Complete Operating and Programming 802Dsl en A TM Sw1 4

SINUMERIK 802D solution line
Machine Controller Handbook T/M
Training Manual Edition 2007.7
Training Material for none Metric Systems

SINUMERIK 802D sl
Operating, Programming
and Service
Turning and Milling
Valid for

Control Software
SINUMERIK 802D sl 1.4
Edition 07.2007
Module content for end users.
Operating and Programming Service

CNC Basic Principles Turning C101
CNC Basic Principles Milling C102 Pushbutton test (MCP) C8
Power On and Referencing C69 LED Diagnosis Drive C9
Control Structure / Navigation C70 LED Diagnosis HMI C10
Basic Program Structure C98 MCPA Board C11
Modality (preparatory functions) C89 Save Data Backup C17
Commonly used G functions - T C91 Restore Data Backup C18
Commonly used G functions - M C92 External data backup and restore C19
Basic Miscellaneous Codes C97 Diagnose PLC program C28
Additional G functions - T C93 Diagnose PLC alarm C31
Additional G functions - M C94 Alarm structure C37
Create part program - Milling C77 Editing of NC Machine data C41
Create part program - Turning C78 Drive Diagnostic parameters C53
Cycles - M C99

Cycles - T C100
Free Contour Programming T C105

Free Contour Programming M C106
File Management - CF card C59

Axis Control - Jog C82
MDA - Turning C75

MDA - Milling C76
Tools Turning - work planes C71

Tools Milling - work planes C72
Work offsets - Turning C73

Work offsets - Milling C74
Automatic C81

RCS 802 Data transfer tool C1
Mold & Die Programming C104

ISO Dialect programming - M C95
ISO Dialect programming - T A-B-C C96
Tools Turning²Milling functions C83

C101 CNC Basic Principles - Turning
1 Brief description
Module Objective:

Upon completion of this module you can understand the basic functionality and requirements of a
CNC controller
Module description:

CNC machines replicate the functions of a manual machine through the use of a sequential program,
WKLVSURJUDPUHSOLFDWHVWKHPRYHPHQWVRIDPDQXDOPDFKLQHWKURXJKWKHVRFDOOHG³&1&SURJUDP´
Geometric relationships of the component to the machine are achieved with (Tool and component)
numeric compensations. These compensations mathematically compensate the difference between
component, Tool and machine.
Module Content:
Fundamentals of CNC Machines

Fundamentals of CNC

Machines
Section 2
SINUMERIK 802D sl Operating and Service Training Manual Page 1 C101
C101
Section 2 Fundamentals of CNC Machines
Notes
The difference between a Manual machine and a CNC machine is a logical
difference based upon numerical values. This overview module and the
following CNC modules should help explain the myth of CNC.
ITS ONLY NUMBERS. No magic !!
Reference position Z
Reference position X
A referenced machine has a defined position.
If theoretically zero for all three axis is commanded, the reference
point of the tool will drive to the zero point of the machine.
³&5$6+´
C101
Notes
Zero Offset
When a work piece offset is activated.
point of the tool will drive to the zero point of the workpiece.
³&5$6+´
C101
Notes
Zero Offset
Tool Offset
When a tool offset is activated.
If theoretically zero for all three axis is commanded, the offset point
of the tool will drive to the zero point of the workpiece.
³1R&UDVK´
C101

C102 CNC Basic Principles - Milling
1 Brief description
Module Objective:

Upon completion of this module you can understand the basic functionality and requirements of a
CNC controller
Module description:

CNC machines replicate the functions of a manual machine through the use of a sequential program,
WKLVSURJUDPUHSOLFDWHVWKHPRYHPHQWVRIDPDQXDOPDFKLQHWKURXJKWKHVRFDOOHG³&1&SURJUDP´
Geometric relationships of the component to the machine are achieved with (Tool and component)
numeric compensations. These compensations mathematically compensate the difference between
component, Tool and machine.
Module Content:
Fundamentals of CNC Machines

Fundamentals of CNC

Machines
Section 2
C102
Notes
The difference between a Manual machine and a CNC machine is a logical
difference based upon numerical values. This overview module and the
following CNC modules should help explain the myth of CNC.
ITS ONLY NUMBERS. No magic !!
Reference position Z
Reference position X
A referenced machine has a defined position.
point of the tool will drive to the zero point of the machine.
³&5$6+´
C102
Notes
Zero Offset
When a work piece offset is activated.
point of the tool will drive to the zero point of the workpiece.
³&5$6+´
C102
Notes
Tool Offset
Zero Offset
When a tool offset is activated.
If theoretically zero for all three axis is commanded, the offset point
of the tool will drive to the zero point of the workpiece.
³1R&UDVK´
C102

C69 Power on and referencing - Turning
1 Description
Module objective:

Upon completion of this module you can switch on the machine and reference the axes.
Module description:

Before you can work with the machine, the control has to be switched on. Axis with incremental
measuring systems have to be referenced, so that the control knows where the axis are in the
machine coordinate system.
It is not necessary to reference axis which have an absolute measuring system.

Module content:
Switch on the control

Referencing the axis

Section 2

Section 3
Section 2 Switch on the control
Notes
The controller starts up normally by switching the machine on.

NOTE: Please take care to follow the switching on guidelines of the
machine manufacturer
Once that the controller is running, all E-Stop switches should normally be
released. Please follow the guidelines of the machine manufacturer.
Section 3 Referencing the axis
Notes
Machines with incremental measuring systems must first be referenced, in
order to synchronise the measuring system with the machine coordinate
system.

The machine should be in a ready condition before trying to travel to
the reference position !!

The controller is automatically in Jog²reference mode after successfully
powering up (JOG REF-mode).

Axis which require reference point approach are those shown below with
an empty circle behind the axis name.
Dependant upon the commissioning of the machine, it is possible to use
DXWRPDWLFUHIHUHQFLQJZKLFKLVVWDUWHGVLPSO\E\XVLQJ³&\FOH6WDUW³
Or by using the following sequence:
Care to be taken

with override
switch.
When the axis are successfully referenced, the referenced symbol will
appear as shown below.

Notes

C69 Power on and referencing - Milling
1 Description
Module objective:

Upon completion of this module you can switch on the machine and reference the axis.

Module description:

Before you can work with the machine, the control has to be switched on. Axes with incremental
measuring systems have to be referenced, so that the control knows where the axis are in the
machine coordinate system.
It is not necessary to reference axis which have an absolute measuring system.

Module content:


Section 2

Section 3
Section 2 Switch on the control
Notes
The controller starts up normally by switching the machine on.

NOTE: Please take care to follow the switching on guidelines of the
machine manufacturer
Once that the controller is running, all E-Stop switches should normally be
released. Please follow the guidelines of the machine manufacturer.
Section 3 Referencing the axis
Notes
Machines with incremental measuring systems must first be referenced, in
order to synchronise the measuring system with the machine coordinate
system.

The machine should be in a ready condition before trying to travel to
the reference position !!

The controller is automatically in Jog²reference mode after successfully
powering up (JOG REF-mode).

Axis which require reference point approach are those shown below with
an empty circle behind the axis name.
Dependant upon the commissioning of the machine, it is possible to use
DXWRPDWLFUHIHUHQFLQJZKLFKLVVWDUWHGVLPSO\E\XVLQJ³&\FOH6WDUW³
Or by using the following sequence:
Care to be taken

with override
switch.
When the axis are successfully referenced, the referenced symbol will
appear as shown below.

Notes

C70 Control structure and navigation - Turning
1 Brief Description
Module objective:

Upon completion of this module you can navigate the control.

Module description:

The 802D SL controller works on the principle of menus with softkeys, and associated to these are
pictures. This module describes navigating these menus.
Module content:
Overview of operating areas and modes

Functionality of the operating areas and modes
Screen layout
Standard softkeys and hotkeys
Hardware

Overview of operating

areas and modes
Section 2
Functionality of the

operating areasand Section 3
modes
Screen layout Section 4
Standard softkeys and

Section 5
hotkeys
Hardware Section 6
Section 2 Overview of operating areas and modes
Notes
The different operating areas of the control are reachable using the opera-
tor panel keyboard.
The following operating areas are available on the control:
Operating area Softkey Function
Operating area Machine Setting functions, Program control,

Measuring tools, Face milling,
Face turning
Program editing, Simulation, Cycle

Operating area Program
support, Block numbering
Zero offsets, Tool parameters, R-

Operating area Offset /
Parameter, Setting data, User
Parameter
data
Operating area Program- Managing the NC program

Manager memory and the CF-Card,
Program selection, Edit functions
List of active alarms

Operating area System /
Alarm
Machine builder specific

Operating area customer
Notes
The different operating modes of the control are reachable using the
screen softkeys..
The following operating modes are available on the control:
Use the REF key on the machine control panel to activate
Ref Point ³5()(5(1&(32,17$3352$&+´
Use the JOG key on the machine control panel to select the JOG
Jog mode.
Use the MDA key on the machine control panel to select the MDA
MDA mode.
Use the AUTO key on the machine control panel to select the
Auto AUTOMATIC mode.
Use the SINGLE BLOCK key on the machine control panel to se-
Single Block
lect SINGLE BLOCK mode.
Section 3 Functionality of the operating areas and modes
Notes
Overview of the softkeys in JOG
Overview of the softkeys in MDA
Notes
Overview of the Softkeys in AUTOMATIC
Overview of the Softkeys in PROGRAM
Section 4 Screen layout
Notes
Screen layout
1
2
3
1 Status Area
2 Application Area
3 Tip and softkey Area
Notes
Status Area
1 2
4
3 6
5
1 Active operating area, active mode

Position:
JOG: 1INC, 10INC, 100INC, 1000INC, VAR INC
MDA
AUTOMATIC
OFFSET
PROGRAM
PROGRAM MANAGER
SYSTEM
2 Alarm and message line

1. Alarm number with alarm text or
2. Message text
3 Program status

RESET Program cancelled/default status
RUN Program running
STOP Program stopped
4 Program control in Automatic mode
5 NC messages
6 Selected part program (main program)
Notes
Tip and softkey area
4
1 3
2
4
1 Recall key

Pressing the recall key lets you return to the next
higher menu level
2 Tip line
Displays tips for the operator
3 MMC status information

Data transfer running

Connection to PLC programming tool active
4 Vertical and horizontal softkey bar
Section 5 Standard softkeys and hotkeys
Notes
Standard softkey
Selecting this softkey to delete the content of the calculator.
Selecting this softkey to quit the screen form.
Selecting this softkey to cancel the input;; the window is
closed.
Selecting this softkey will complete your input and start the
calculation.
Selecting this softkey will complete your input and accept

the values you have entered.
The calculator function can be activated from any operating

DUHDXVLQJ³6+,)7´DQG³ ´
If the input field is already occupied by a value, the function
will accept this value into the input line of the calculator.
When you press the Input key, the result is calculated and
displayed in the calculator.
Selecting the Accept softkey enters the result in the input
field at the current cursor position of the part program editor
and closes the calculator automatically.
Hotkeys

This operator control can be used to select, copy, cut and de-
leted text using special key commands. These functions are
available for the part program editor and for input fields.

CTRL + C Copy
CTRL + B Select
CRTL + X Cut
CRTL + V Paste
ALT + L Switch between upper/lower case
ALT + H Help system
Or Info key
Section 6 Hardware
Notes
Key definition of CNC keyboard (Vertical Format)
Section 6 Hardware
Notes
Key definition of machine control panel
[VAR]
Jog
Ref Point
Auto
Single Block
MDA
Spindle Left
Spindle Stop
Spindle Right
Reset
Rapid
Cycle Stop

Notes

C70 Control structure and navigation - Milling
1 Brief Description
Module objective:

Upon completion of this module you can navigate the control.

Module description:

The 802D SL controller works on the principle of menus with softkeys, and associated to these are
pictures. This module describes navigating these menus.
Module content:
Overview of operating areas and modes

Functionality of the operating areas and modes
Screen layout
Standard softkeys and hotkeys
Hardware

Overview of operating

areas and modes
Section 2
Functionality of the

operating areasand Section 3
modes
Screen layout Section 4
Standard softkeys and

Section 5
hotkeys
Hardware Section 6
Section2 Overview of operating areas and modes
Notes
The different operating areas of the control are reachable using the opera-
tor panel keyboard.
The following operating areas are available on the control:
Operating area Softkey Function
Operating area Machine Setting functions, Program control,

Measuring tools, Face milling,
Face turning
Program editing, Simulation, Cycle

Operating area Program
support, Block numbering
Zero offsets, Tool parameters, R-

Operating area Offset /
Parameter, Setting data, User
Parameter
data
Operating area Program- Managing the NC program

Manager memory and the CF-Card,
Program selection, Edit functions
List of active alarms

Operating area System /
Alarm
Machine builder specific

Operating area customer
Notes
The different operating modes of the control are reachable using the
screen softkeys..
The following operating modes are available on the control:
Use the REF key on the machine control panel to activate
Ref Point ³5()(5(1&(32,17$3352$&+´
Use the JOG key on the machine control panel to select the JOG
Jog mode.
Use the MDA key on the machine control panel to select the MDA
MDA mode.
Use the AUTO key on the machine control panel to select the
Auto AUTOMATIC mode.
Use the SINGLE BLOCK key on the machine control panel to se-
Single Block
lect SINGLE BLOCK mode.
Notes
Overview of the softkeys in JOG
Overview of the softkeys in MDA
Notes
Overview of the Softkeys in AUTOMATIC
Overview of the Softkeys in PROGRAM
Notes
Screen layout
1
2
3
1 Status Area
2 Application Area
3 Tip and softkey Area
Notes
Status Area
1 2
4
3 6
5
1 Active operating area, active mode

Position:
JOG: 1INC, 10INC, 100INC, 1000INC, VAR INC
MDA
AUTOMATIC
OFFSET
PROGRAM
PROGRAM MANAGER
SYSTEM
2 Alarm and message line

1. Alarm number with alarm text or
2. Message text
3 Program status

RESET Program cancelled/default status
RUN Program running
STOP Program stopped
4 Program control in Automatic mode
5 NC messages
6 Selected part program (main program)
Notes
Tip and softkey area
4
1 3
2
4
1 Recall key

Pressing the recall key lets you return to the next
higher menu level
2 Tip line
Displays tips for the operator
3 MMC status information

Data transfer running

Connection to PLC programming tool active
4 Vertical and horizontal softkey bar
Section 5 Standard softkeys and hotkeys
Notes
Standard softkey
Selecting this softkey to delete the content of the calculator.
Selecting this softkey to quit the screen form.
Selecting this softkey to cancel the input;; the window is
closed.
Selecting this softkey will complete your input and start the
calculation.
Selecting this softkey will complete your input and accept

the values you have entered.
The calculator function can be activated from any operating

DUHDXVLQJ³6+,)7´DQG³ ´
If the input field is already occupied by a value, the function
will accept this value into the input line of the calculator.
When you press the Input key, the result is calculated and
displayed in the calculator.
Selecting the Accept softkey enters the result in the input
field at the current cursor position of the part program editor
and closes the calculator automatically.
Hotkeys

This operator control can be used to select, copy, cut and de-
leted text using special key commands. These functions are
available for the part program editor and for input fields.

CTRL + C Copy
CTRL + B Select
CRTL + X Cut
CRTL + V Paste
ALT + L Switch between upper/lower case
ALT + H Help system
Or Info key
Section 6 Hardware
Notes
Key definition of CNC keyboard (Vertical Format)
Section 6 Hardware
Notes
Key definition of machine control panel
[VAR]
Jog
Ref Point
Auto
Single Block
MDA
Spindle Left
Spindle Stop
Spindle Right
Reset
Rapid
Cycle Stop

Notes

C98 Basic program structure - Turning
1 Brief description
Module objective:

Upon completion of this module you will understand the basic structure of a NC program.

Module description:

We use a basic structure when writing a program to give some kind of order to the program, this will
DOVRKHOSZKHQSHUIRUPLQJD³%ORFNVHDUFK´

Module content:

Basic structure
Basic structure for turning
Basic structure for milling

Basic structure
Section 2
Basic structure for

turning Section 3
C98
Section 2 Basic structure
Notes
There are five basic parts to an NC program.

1. Basic startup G functions.
2. Call tool and set spindle speed, feed, coolant.
3. Set geometry to cut component.
4. Tool to safe position
5. End of program

G00 G90 G95 G40 G18 G70 Basic G functions for program
LIMS=2500
G54

T1 D1 Call tool etc
G96 S250 F0.006 M03 M08

G00 X0.0 Z0.1
«
«
«
« Geometry for component
«
«
«
G00 G40 Z2.0

X8.0 Z8.0 Safe position for tool change

M30 End of program

You will note that for each tool there is always :

Call tool etc
Geometry for component
Safe position for tool change

This will be the same for every tool that is written in the NC program

If you keep to a good basic structure, this will make the program safer to
run and easier to perform a block search.
C98
Section 3 Basic structure for turning
Notes
This is the basic structure of NC program for turning

G00 G90 G95 G40 G18 G70
LIMS=2500 Basic G functions for program
G54

T1 D1 Call tool etc
G96 S750 M03 M08

G00 X2.0470 Z0.1
G01 X-0.0800 F0.006
G00 Z0.0800
X0.7874
G01 Z-0.7874 Geometry for component
X1.1811 Z-0.9842
X1.7716
Z-1.9685
X2.0470

G00 G40 Z2.0

T4 D1 Call tool etc
G95 S1500 M04 M08

G00 X0.0 Z0.0800
G01 Z-0.9842 F0.0098 Geometry for component
G00 Z0.0800

G00 G40 Z0.0800

M30 End of program
C98

Notes
C98

C98 Basic program structure - Milling
1 Brief description
Module objective:

Upon completion of this module you will understand the basic structure of a NC program.

Module description:

We use a basic structure when writing a program to give some kind of order to the program, this will
DOVRKHOSZKHQSHUIRUPLQJD³%ORFNVHDUFK´

Module content:
Basic structure
Basic structure for milling

Basic structure
Section 2
Basic structure for

milling Section 3
C98
Section 2 Basic structure
Notes
There are five basic parts to an NC program.

1. Basic startup G functions.
2. Call tool and set spindle speed, feed, coolant.
3. Set geometry to cut component.
4. Tool to safe position
5. End of program

G00 G90 G94 G40 G17 G70 Basic G functions for program

T1
M6 Call tool etc
G95 S1500 F0.006 M03 M08

G00 G54 X0.0 Y0.0 Z2.0
«
«
«
« Geometry for component
«
«
«
G00 G40 Z2.0

X0.0 Y8.0 Z8.0 Safe position for tool change

M30 End of program

You will note that for each tool there is always :

Call tool etc
Geometry for component
Safe position for tool change

This will be the same for every tool that is written in the NC program

If you keep to a good basic structure, this will make the program safer to
run and easier to perform a block search.
C98
Section 3 Basic structure for milling
Notes
This is the basic structure of NC program for milling

N10 G00 G90 G94 G40 G17 G70 Basic G functions for program

N20 T1
N30 M6 Call tool etc
N40 G95 S2500 F0.0098 M03 M08

N50 G00 G54 X0.0 Y0.0 Z2.0
N60 MCALL CYCLE82(0.1968, 0.0000, 0.0800, -0.0800, 0.0000, 0.0000)
N70 X0.3937
N80 X0.7874
N90 X1.1811 Geometry for component
N100 X1.5748
N110 X1.9685
N120 X2.3622
N130 MCALL

N140 G00 G40 Z2.0
N150 X0.0 Y8.0 Z8.0 Safe position for tool change

N160 T4
N170 M06 Call tool etc
N180 G95 S1500 F0.009 M05 M08

N190 G00 G54 X0.0 Y0.0 Z2.0
N200 MCALL CYCLE82(0.1968, 0.0000, 0.0800, -0.0800, 0.0000, 0.0000)
N210 X0.3937
N220 X0.7874
N230 X1.1811 Geometry for component
N240 X1.5748
N250 X1.9685
N260 X2.3622
N270 MCALL

N280 G00 G40 Z2.0
N290 X0.0 Y8.0 Z8.0 Safe position for tool change

N300 M30 End of program
C98

Notes
C98

C89 Modality (Preparatory functions) - Turning
1 Brief description
Module objective:

Upon completion of this module you will understand Preparatory functions (G-Codes).

Module description:

We use preparatory G functions according to there appropriate functional group to instruct a machine
what to do via the customers NC program.

Module content:
G function overview
G function window display

G function overview
Section 2
G function window dis-

play Section 3
C89
Section 2 G function overview
Notes
G function (preparatory function).

The G functions are divided into G groups.

Only one G function from each group can be written in a single block.

A G function can either be modal (until canceled by another function from
the same group), or non-modal (only effective for that block it is written
in).
Modal example:

G00 G90 G95 G40 G18
LIMS=2500
G54
T1 D1
G96 S1000 M03
G01 X0.0 Z0.0 F0.35
X20.0 1
Z-10.0
X30.0
Z-20.0
X40.0
G00 Z50.0 2
M30
1 These blocks are performed at a given feed rate, because G01 is
modal and will not change until another code from the same group
is entered
2 At this block the speed of motion will change due to the change of
the G function group, from G01 to G00.
Non-modal example:

G00 G90 G95 G40 G18
LIMS=2500
G54
T2 D1
G96 S1000 M03
X0.0 Z50.0
G01 Z0.0 F0.35
G04 F10.0 3
G00 Z50.0
M30
3 This G function is only effective in this block, to use this function
again you must type it in again in another block.
C89
Notes
Group 1: Modally valid motion commands

Name Meaning Machine
G00 Rapid traverse M/T
G01*# Linear interpolation M/T
G02 Circular interpolation clockwise M/T
G03 Circular interpolation counter-clockwise M/T
G33 Thread cutting with constant lead M/T
Group 2: Non-modally valid motion, dwell

G04 Dwell time preset M/T
G63 Tapping without synchronization M/T
G74 Reference point approach with synchronization M/T
G75 Fixed point approach M/T
Group 3: Programmable frame, working area limitation

TRANS Translation, programmable M/T
ROT Rotation, programmable M/T
SCALE Scaling, programmable M/T
MIRROR Mirroring, programmable M/T
Minimum working area limitation/spindle speed limita-
G25 M/T
tion
Maximum working area limitation/spindle speed limi-
G26 M/T
tation
Group 6: Plane selection

G17# Plane selection 1st - 2nd geometry axis M/T
G18* Plane selection 3rd - 1st geometry axis M/T
G19 Plane selection 2nd - 3rd geometry axis M/T
Default for turning * / default for milling #

M = milling / T = turning
C89
Notes
Group 7: Tool radius compensation

Name Meaning machine
G40*# No tool radius compensation M/T
G41 Tool radius compensation left of contour M/T
G42 Tool radius compensation right of contour M/T
Group 8: Settable zero offset

Deactivate all settable G54²G59 if G500 not contain
G500*# M/T
a value
G54 Settable zero offset M/T
Group 9: Frame suppression

G53 Suppression of current zero offset: including active M/T
settable frame G54 - G59
Group 10: Exact stop - continuous-path mode

G60*# Velocity reduction, exact positioning M/T
G64 Continuous ± path mode M/T
Group 11: Exact stop, non-modal

G09 Velocity reduction, exact positioning M/T

C89
Notes
Group 13: Workpiece measuring inch/metric

G70 Input system inches (lengths) M/T
G71*# Input system metric (lengths) M/T
Group 14: Workpiece measuring absolute/incremental

G90*# Absolute dimensions input M/T
G91 Incremental dimension input M/T
Group 15: Feed type

G94# Linear feed mm/min, inch/min M/T
G95* Rotational feed in mm/rev, inch/rev M/T
G96 Constant cutting speed (type of feed as for G95) ON T
G97 Constant cutting speed (type of feed as for G95) OFF T
Group 16: Feed override on inside and outside curvature

CFC*# Constant feed at contour M/T
CFTCP Constant feed in tool center point (center-point path) M/T
Constant feed at internal radius, acceleration at exter-

CFIN M/T
nal radius

C89
Section 3 G function window display
Notes
To look at the active G-codes, you can activate a window called
G FUNCTION.

Follow this sequence.
7KLV³*IXQFWLRQ´VRIWNH\LVSUHVHQWLQPRGHV
C89
Notes
In this window, it will show you every group number and the active G-code
for that group at that present time.

Use the button to scroll down or up to search for the required G-code
group.
Page Page
up Down
C89

Notes
C89

C89 Modality (Preparatory functions) - Milling
1 Brief description
Module objective:

Upon completion of this module you will understand Preparatory functions (G-Codes).

Module description:

We use preparatory G functions according to there appropriate functional group to instruct a machine
what to do via the customers NC program.

Module content:
G function overview
G function window display

G function overview
Section 2
G function window dis-

play Section 3
C89
Notes
G function (preparatory function).

The G functions are divided into G groups.

Only one G function from each group can be written in a single block.

A G function can either be modal (until canceled by another function from
the same group), or non-modal (only effective for that block it is written
in).
Modal example:

G00 G90 G94 G40 G17
T1 D1
G54 S1000 M03
G01 X0.0 Y0.0 Z0.0 F200
X100.0
Y100.0 1
X0.0
Y0.0
G00 Z50.0 2
M30

1 These blocks are performed at a given feed rate, because G01 is
modal and will not change until another code from the same group
is entered
2 At this block the speed of motion will change due to the change of
the G function group, from G01 to G00.
Non-modal example:

G00 G90 G94 G40 G17
T2 D1
G54 S1000 M03
X0.0 Y0.0 Z50.0
G01 Z0.0 F200
G04 F10.0 3
G00 Z50.0
M30
3 This G function is only effective in this block, to use this function
again you must type it in again in another block.
C89
Notes
Group 1: Modally valid motion commands

G00 Rapid traverse M/T
G01*# Linear interpolation M/T
G02 Circular interpolation clockwise M/T
G03 Circular interpolation counter-clockwise M/T
G33 Thread cutting with constant lead M/T
Group 2: Non-modally valid motion, dwell

G04 Dwell time preset M/T
G63 Tapping without synchronization M/T
G74 Reference point approach with synchronization M/T
G75 Fixed point approach M/T
Group 3: Programmable frame, working area limitation

TRANS Translation, programmable M/T
ROT Rotation, programmable M/T
SCALE Scaling, programmable M/T
MIRROR Mirroring, programmable M/T
Minimum working area limitation/spindle speed limita-
G25 M/T
tion
Maximum working area limitation/spindle speed limi-
G26 M/T
tation
Group 6: Plane selection

G17# Plane selection 1st - 2nd geometry axis M/T
G18* Plane selection 3rd - 1st geometry axis M/T
G19 Plane selection 2nd - 3rd geometry axis M/T

C89
Notes
Group 7: Tool radius compensation

Name Meaning machine
G40*# No tool radius compensation M/T
G41 Tool radius compensation left of contour M/T
G42 Tool radius compensation right of contour M/T
Group 8: Settable zero offset

Deactivate all settable G54²G59 if G500 not contain
G500*# M/T
a value
Group 9: Frame suppression

G53 Suppression of current zero offset: including active M/T
settable frame G54 - G59
Group 10: Exact stop - continuous-path mode

G60*# Velocity reduction, exact positioning M/T
G64 Continuous ± path mode M/T
Group 11: Exact stop, non-modal

G09 Velocity reduction, exact positioning M/T

C89
Notes
Group 13: Workpiece measuring inch/metric

G70 Input system inches (lengths) M/T
G71*# Input system metric (lengths) M/T
Group 14: Workpiece measuring absolute/incremental

G90*# Absolute dimensions input M/T
G91 Incremental dimension input M/T
Group 15: Feed type

G94# Linear feed mm/min, inch/min M/T
G95* Rotational feed in mm/rev, inch/rev M/T
G96 Constant cutting speed (type of feed as for G95) ON T
G97 Constant cutting speed (type of feed as for G95) OFF T
Group 16: Feed override on inside and outside curvature

CFC*# Constant feed at contour M/T
CFTCP Constant feed in tool center point (center-point path) M/T
Constant feed at internal radius, acceleration at exter-

CFIN M/T
nal radius

C89
Notes
To look at the active G-codes, you can activate a window called
G FUNCTION.

7KLV³*IXQFWLRQ´VRIWNH\LVSUHVHQWLQPRGHV
C89
Notes
In this window, it will show you every group number and the active G-code
for that group at that present time.

Use the button to scroll down or up to search for the required G-code
group.
Page Page
up Down
C89

Notes
C89

C91 Commonly used G functions - Turning
1 Brief description
Module objective:

Upon completion of this module you will understand commonly used G functions (G-Codes) for turn-
ing in detail.

Module description:

We use G functions according to their appropriate functional group to instruct a machine what to do,
but a structure should be kept to.

Module content:
G functions in detail

Example turning program
Example drilling program


Section 2
Example turning pro-

gram Section 3
Example drilling pro-

gram Section 4
C91
Section 2 G function in detail
Notes
Rapid traverse movement G00

Function
You can use a rapid traverse movement to position the tool rapidly,
to travel around the Workpiece or to approach tool change locations.
Note: when there is a two axis movement, both axes interpolate to
their end position, arriving at the same time.

Programming
G00 X.. Z..
Or
G0 X.. Z..

Linear interpolation G01

Function
With G01, the tool travels along a straight line.

Programming
G01 X.. Z.. F..
Or
G1 X.. Z.. F..

Circular interpolation, G02/G03

Function
This function allows you to program an arc either in clockwise (G02)
or counter-clockwise (G03) direction.

Programming
G02/G03 X.. Z.. I=AC(..) K=AC(..) Absolute centre point
Or
G02/G03 X.. Z.. I.. K.. Incremental centre point
Or
G02/G03 X.. Z.. CR=.. Circle radius CR=

C91
Notes
Dwell time G4

Function
You can use G4 to interrupt workpiece
machining between two NC blocks for the
programmed length of time, e.g. dwell at
bottom of hole.

Programming
G4 F.. F = Time (in seconds)
Or
G4 S.. S = Rotations

Plane selection G17

Function +X
This plane is selected when milling or drill-
ing at the end face of the turned part.

Programming -Z
+Z
G17

-X
Plane selection G18

Function
This is the default plane, and is used when
stock removal, threading, and grooving of
the turned part.

Programming
G18

Plane selection G19

Function
This plane is selected when milling or drill- +X
ing at the peripheral surface of the
turned part.

-Z
Programming +Z
G19
-X
C91
Notes
Tool Compensation
Width of error when NO tool
Width of error when NO tool offset
Without tool compensa- offset applied.
applied.
tion, there will always be

an error when turning a
contour, radius, and P1 + Is where tool is
P1 = Is point where tool is
chamfer, that involves a theoretically driven
theoretically driven around
around from, when no P2
from, when no tool offset
two axis movement. tool offset applied
applied

P2 = Is point where tool
P2 = Is point where tool is
is theoretically driven P1
theoretically driven around
around from, when tool
from, when tool offset is
offset is applied with
applied with radius of tip.
radius of tip.
Tool radius compensation G40

Function
To deactivate tool compensation

Programming
G40


Function
To activate tool compensation, with the tool operating to the left of
the contour in the machining direction. Most commonly used when
boring inside a hole towards the chuck

Programming
G41


Function
To activate tool compensation, with the tool operating to the right of
the contour in the machining direction. Most commonly used when
turning externally towards the chuck

Programming
G42

C91
Notes
Zero offset G54

Function
The settable zero offset relates the Workpiece zero on all axes to the
machine zero offset.

Programming
G54

Absolute dimension G90

Function
With the G90 command all dimensions are related from your active
zero workpiece.

Programming
G90
X.. Z..

Feed rate G95

Function
This is how the feedrate will act to the axis that is moving in relation-
ship to the spindle
The spindle will be programmed in direct RPM and the feedrate will
be MM/REV
G95 is usually used when drilling.

Programming
G95 S.. F..

C91
Notes
Feed rate G96

Function
ship to the spindle
The spindle will be programmed in constant surface speed (m/min)
and the feedrate will be MM/REV
G96 is usually used when turning.

Programming d
G96 S.. F..

Note: as the tool gets closer to the
centre line the spindle speed will
increase. As the tool gets further
away from the centre line the spin-
dle speed will decrease.

Exact stop/continuous-path control: G09, G60, G64

Function
Will set the block end behavior movement and how to continue with
the next. E.g. G09/G60 the velocity for reaching the exact end posi-
tion is to decelerate the velocity to zero. With G64, the object is to
avoid deceleration at the end of the block.

Programming
G09 ;; Exact stop - non-modal

G60 ;; Exact stop - modally effective
G64 ;; Continuous path/control mode

G60 G64
C91
Section 3 Example turning program
Notes
G00 G90 G95 G40 G18 ;;default G-code line
LIMS=2500
G54 ;;zero offset for workpiece
T1 D1 ;;call tool
G96 S820 M03 ;;speed in FT/MIN feed REV/MIN
G00 X1.9685 Z0.0 ;;rapid to safe position
G01 X-0.0787 F0.0196 ;;face off component
G00 Z0.0787 ;;rapid off front face
X0.7874 ;;rapid to diameter
G01 G42 Z0.0 ;;feed onto front face with tool comp
Z-0.7874
G02 X1.1811 Z-0.9842 I0.1968 K0.0 ;;clockwise arc using I and K
G03 X1.3385 Z-1.0629 CR=0.0787 ;;counterclockwise arc
G01 Z-1.1811
X1.9685 Z-1.5748 ;;feed up a slope
Z-1.9685
X2.0472 ;;feed off of finished component
G00 G40 X6.0 Z6.0 ;;rapid to tool change position
M30 ;;end of program
This is the same program typed into the control
C91
Section 3 Example turning program
Notes
The same program run in simulation
C91
Section 4 Example drilling program
Notes
G00 G90 G95 G40 G17 ;;default G-code line

LIMS=2500
G54 ;;zero offset for workpiece
T6 D1 ;;call tool
G95 S2500 M03 ;;spindle speed in RPM feed REV/MIN
G00 X0.0 Z0.0787 ;;rapid to safe position
G01 Z-0.3937 F0.0039 ;;feed to bottom of hole
G00 Z0.0787 ;;rapid out of hole
G00 G40 X6.0 Z6.0 ;;rapid to tool change position
This is the same program typed into the control
C91
Notes
The same program run in simulation
C91

C92 Commonly used G functions - Milling
1 Brief description
Module objective:

Upon completion of this module you will understand commonly used G functions (G-Codes) for mill-
ing in detail.

Module description:

We use G functions according to their appropriate functional group to instruct a machine what do ,
but a certain structure should be kept to.

Module content:

Example contour program
Example drilling program


Section 2
Example contour pro-

gram Section 3
Example drilling pro-

gram Section 4
C92
Section 2 G functions in detail
Notes
Rapid traverse movement G00

Function
You can use rapid traverse movement, to position the tool rapidly, to
travel around the workpiece or to approach tool change locations.
Note: when there is a two axis movement, both axes interpolate to
their end position, arriving at the same time.

Programming
G00 X.. Y.. Z..
Or
G0 X.. Y.. Z..

Linear interpolation G01

Function
With G01, the tool travels along a straight
line.

Programming
G01 X.. Y.. Z.. F..
Or
G1 X.. Y.. Z.. F..


Function

Programming
G02/G03 X.. Y.. Z.. I=AC(..) J-AC(..) K=AC(..)
absolute centre point
Or
G02/G03 X.. Y.. Z.. I.. J.. K..
Incremental centre point
Or
G02/G03 X.. Y.. Z.. CR=..
Circle radius CR=

C92
Notes
Dwell time G4

Function
You can use G4 to interrupt workpiece machining between two NC
blocks for the programmed length of time, e.g. dwell at bottom of
hole.

Programming
G4 F.. F = Time (time in seconds)
Or
G4 S.. S = Rotations

Plane selection G17

Function
To select the infeed feed axis when milling or drilling, this is the de-
fault G function.

Programming
G17

C92
Notes

Function
To deactivate tool compensation

Programming
G40


Function
To activate tool compensation, with the tool operating to the left of
the contour in the machining direction.

Programming
G41


Function
To activate tool compensation, with the tool operating to the right of
the contour in the machining direction.

Programming
G42

C92
Notes
Zero offset G54 to G59

Function
The settable zero offset relates the workpiece zero on all axes to the
machine zero offset.

Programming
G54 to G59

Absolute dimension G90

Function
With the G90 command all dimensions are related from your active
zero offset.

Programming
G90
X.. Y.. Z..

C92
Notes
Feed rate G94

Function
ship to the spindle.
be MM/MIN.
Note: the axis will move without the spindle rotating.

Programming
G94
S.. F..

MM/MIN
Feed rate G95

Function
ship to the spindle.
be MM/REV

Programming
G95
S.. F..

MM/REV

Exact stop/continuous-path control: G09, G60, G64

Function
Will set the block end behavior movement and to continue with the
next. E.g. G09/G60 the objective for reaching the exact end position
is to decelerate the velocity to zero. With G64, the object is to avoid
deceleration at the end of the block.

Programming
G09 ;; Exact stop - non-modal

G60 ;; Exact stop - modally effective
G64 ;; Continuous path-control mode

G60 G64
C92
Section 3 Example contour program
Notes
G00 G90 G94 G40 G17 ;;Basic G-code commands
T1 D1 ;;call tool
G94 S2500 M03 F20 ;;speed in RPM feed INCH/MIN
G00 G54 X2.16 Y2.16 Z2.0 ;;start of contour
Z0.0 ;;rapid to safe position
G01 Z-0.196 ;;feed onto workpiece
G01 G42 Y1.9685 ;;apply cutter compensation
X-1.7716 ;;coordinates for contour
G03 X-1.9685 Y1.7716 I0.0 J-0.168 ;;arc using incremental start point
G01 Y-1.575 ;;coordinates for contour
G02 X-1.575 Y-2.0 CR=0.393 ;;arc using circle radius
G01 X1.377 ;;coordinates for contour
G03 X2.0 Y-1.377 I=AC(1.377) J=AC(-1.377) ;;arc using absolute start point
G01 Y2.165 ;;coordinates for contour
G00 G40 Z2.0 ;;cancel cut comp
X0.0 Y8.0 Z8.0 ;;safe tool change position
This is the same program typed into the control:
C92
Section 3 Example contour program
Notes
The same program run in simulation:
C92
Notes
G00 G90 G95 G40 G17 ;;basic G-code commands
T1 D1 ;;call tool
G95 S1500 M03 F0.006 ;;spindle speed in RPM feed MM/REV
G00 G54 X0.0 Y0.0 Z2.0 ;;rapid to safe position start of contour
Z0.080 ;;rapid to safe position
G04 F0.020 ;;dwell at bottom of hole
X-2.0 ;;coordinates for drilling
G04 F0.020 ;;dwell at bottom of hole
G00 G40 Z2.0 ;;rapid to safe height
X0.0 Y8.0 Z8.0 ;;safe tool change position
This is the same program typed into the control:
C92
Notes
The same program run in simulation:
C92

C97 Miscellaneous codes - Turning
1 Brief description
Module objective:

Upon completion of this module you will understand miscellaneous codes.

Module description:

We use miscellaneous codes as a simple switch, to instruct a machine to switch ON/OFF various
function via the customers NC program.

Module content:

Miscellaneous codes
Miscellaneous functions (M)
T, D, F, S, window display
M, H, window display

Miscellaneous codes
Section 2
Miscellaneous func-
tions (M) Section 3
T, D, F, S, window dis-

Section 4
play

Section 5
C97
Section 2 Miscellaneous codes
Notes
Tool T

Function
The tool selection takes place when the T word is programmed.

Tool change is performed directly using T word.

Programming
T1 D1 WRROFDOOIRU³WXUQLQJ´

Tool offset number D

Function
It is possible to assign 1 to 9 data fields with different tool offset
blocks to a specific tool.
If no D word is written, D1 is automatically in effect.
If D0 is programmed, the offset for the tool is inactive.

Programming
'« WRRORIIVHWQXPEHU«
D0 ;; no offset active

C97
Notes
Path Velocity F

Function

The path velocity is determined by the programmed F word. All axes
can be traversed simultaneously.

Programming

G01 G95 X100 F0.1 S500 ;; feed rate = 0.1mm/rev


Spindle speed S

Function

The spindle speed is programmed in r.p.m. under the address S,
provided that there is a controlled spindle on the machine.

Programming

S1000 M03 ;; Spindle accelerates Clock²wise to
1000rpm
«
S500 ;; speed change

C97
Section 3 Miscellaneous functions
Notes
The miscellaneous functions M initiates switching operations, such as
³FRRODQW212))´DQGRWKHUIXQFWLRQV

Various M functions have already been assigned to the CNC control, M
functions not already assigned to the CNC control are reserved for free
assignment by the machine tool manufacturer.
Program stop (M00, M01)

Function
When placed between axis movements, this command will stop the
NC program until the cycle start button is pressed again.

Programming
M00 ;; unconditional stop (you must press cycle start)
M01 ;; conditional stop
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0LVFRQGLWLRQDOFDQEHDFWLYDWHGRUGHDFWLYDWHGLQWKH³$872´SDJH
By following this sequence.
1
1 In the STATUS area the control will show you that M01 has been
activated.
C97
Notes
End of program, M02, M17, M30

Function
A program is terminated with M2, M17 or M30 and reset to the begin-
ing of the program. M02, M17 are usually used to return to the main
program from a program call.

Programming
M02 ;; program stop and reset to beginning
Direction of spindle rotation (M03 - M04 - M05)

Functions
To specify the direction of rotation of the spindle or stop the rotation.

Programming
M03 ;; clockwise direction

M04 ;; counter clockwise direction

M05 ;; stop the spindle
Tool change (M06)

Function
M06 is usually used on a milling machine to call up and run a cycle,
this being written by the machine tool builder. The cycle will change
the tool from the spindle into the magazine either by moving the
magazine to the spindle or using an arm of some sort.

Programming
T01
M06 tool change for a milling machine
C97
Notes
Coolant ON/OFF (M08 - M09)

Function
To switch ON and OFF of coolant system on machine.

Programming
M08 ;; switch on of coolant system
M09 ;; switch off of coolant system

C97
Section 4 T, D, F, S, window display
Notes
To find out which miscellaneous codes are active (T, D, F, S,)

2
2 This screen will show you all active T, D, F, S, values that are
being used in the NC program at that point in time.
7KLV³7')6´ZLQGRZLVDYDLODEOHLQDOOWKHVHWKUHHPRGHV
C97
Section 5 M and H window display
Notes
To find out which miscellaneous functions are active (M and H)

C97
Notes
3
3 This screen will show you all active M and H values that are
This window is available in all these three modes:
C97

Notes
C97

C97 Miscellaneous codes - Milling
1 Brief description
Module objective:

Upon completion of this module you will understand miscellaneous codes.

Module description:

We use miscellaneous codes as a simple switch, to instruct a machine to switch ON/OFF various
function via the customers NC program.

Module content:

Miscellaneous codes
Miscellaneous functions (M)
T, D, F, S, window display

Miscellaneous codes
Section 2
Miscellaneous func-
tions (M) Section 3
T, D, F, S, window dis-

Section 4
play

Section 5
C97
Notes
Tool T

Function
The tool selection takes place when the T word is programmed.
However the change of tool depends:
Tool change is performed either directly using T word for
³WXUQLQJ´
Or tool change is performed with the T word with an additional
LQVWUXFWLRQ0VHHVHFWLRQ³PLVFHOODQHRXVIXQFWLRQVIRUPLOO
ing

Programming
T1 D1 WRROFDOOIRU³WXUQLQJ´

T1
M6 WRROFDOOIRU³PLOOLQJ´

Tool offset number D

Function
It is possible to assign 1 to 9 data fields with different tool offset
blocks to a specific tool.
If no D word is written, D1 is automatically in effect.
If D0 is programmed, the offset for the tool is inactive.

Programming
'« WRRORIIVHWQXPEHU«
D0 ;; no offset active

C97
Notes
Path Velocity F

Function

The path velocity is determined by the programmed F word. All axes
can be traversed simultaneously.

Programming

G01 G94 X100 F500 ;; feed rate = 500mm/min


Spindle speed S

Function

The spindle speed is programmed in r.p.m. under the address S,
provided that there is a controlled spindle on the machine.

Programming

S1000 M03 ;; Spindle accelerates Clock²wise to
1000rpm
«
S500 ;; speed change

C97
Notes
The miscellaneous functions M initiates switching operations, such as
³FRRODQW212))´DQGRWKHUIXQFWLRQV

Various M functions have already been assigned to the CNC control, M
functions not already assigned to the CNC control are reserved for free
assignment by the machine tool manufacturer.
Program stop (M00, M01)

Function
When placed between axis movements, this command will stop the
NC program until the cycle start button is pressed again.

Programming
M00 ;; unconditional stop (you must press cycle start)
M01 ;; conditional stop
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0LVFRQGLWLRQDOFDQEHDFWLYDWHGRUGHDFWLYDWHGLQWKH³$872´SDJH
By following this sequence.
1
1 In the STATUS area the control will show you that M01 has been
activated.
C97
Notes
End of program, M02, M17, M30

Function
A program is terminated with M2, M17 or M30 and reset to the begin-
ing of the program. M02, M17 are usually used to return to the main
program from a program call.

Programming

Direction of spindle rotation (M03 - M04 - M05)

Functions
To specify the direction of rotation of the spindle or stop the rotation.

Programming
M03 ;; clockwise direction

M04 ;; counter clockwise direction

M05 ;; stop the spindle

Tool change (M06)

Function
M06 is usually used on a milling machine to call up and run a cycle,
this being written by the machine tool builder. The macro will change
the tool from the spindle into the magazine either by moving the
magazine to the spindle or using an arm of some sort.

Programming
T01
M06 tool change for a milling machine
C97
Notes
Coolant ON/OFF (M08 - M09)

Function
To switch ON and OFF of coolant system on machine.

Programming
M08 ;; switch on of coolant system
M09 ;; switch off of coolant system

C97
Section 4 T, D, F, S, window display
Notes
To find out which miscellaneous codes are active (T, D, F, S,)

2
2 This screen will show you all active T, D, F, S, values that are
7KLV³7')6´ZLQGRZLVDYDLODEOHLQDOOWKHVHWKUHHPRGHV
C97
Notes
To find out which miscellaneous functions are active (M and H)

C97
Notes
3
3 This screen will show you all active M and H values that are
This window is available in all these three modes:
C97

Notes
C97

C93 Additional G functions - Turning
1 Brief description
Module objective:

Upon completion of this module you will understand commonly used additional used G functions (G-
Codes) in detail.

Module description:

We use G functions to instruct a machine what to do, but a structure should be kept to.

Module content:
Additional G functions in more detail

Example program

Additional G functions
in more detail
Section 2
Example program
Section 3
C93
Section 2 Additional G functions in more detail
Notes
Radius/diameter dimensional notation: DIAMOF, DIAMON

Function
For the machining of parts on turning machines, it is typical to pro-
gram geometry data as diameter dimensions. When necessary, it is
possible to switch to radius geometry in the program.

Programming
DIAMOF ;; radius dimensioning
DIAMON ;; diameter dimensioning

This function is typical used on TURN/MILL machines
Upper speed limit for G96: LIMS

Function
When G96 is used in a program, the spindle speed will vary accord-
ing to the diameter being cut. It is usual to cap the maximum spindle
speed within the program for various reasons e.g. bar feed work or
extremely small diameter component.

Programming
LIMS= ;;upper speed limit for G96

C93
Notes
Spindle positioning: SPOS

Function
With the function SPOS= you can position the spindle in a specific
angular position. The spindle is held in the position by position con-
trol.
Programming
SPOS= ;; absolute dimension position
SPOS= IC(..) ;; incremental dimension position

Master spindle: SETMS

Function
The master spindle is defined by machine data, and generally is the
main spindle. A different spindle can be defined as master spindle in
the program (driven tooling).

Programming
SETMS ;; configured spindle is now the master spindle
SETMS(n) ;; spindle (n) is now master spindle
S2

S1

C93
Section 2
Notes
Rounding, chamfer - RND, CHF, CHR

Function
You can insert a chamfer (CHF of CHR) or rounding (RND) elements
into a contour intersection.

Programming
CHF= ;; insert chamfer, value is length of chamfer
CHR= ;; insert chamfer, value is side length of chamfer
RND= ;; insert rounding, value is radius of rounding

Angle - ANG

Function
If only one of the end points is known for a straight line, and an angu-
lar dimension is given on the drawing, this can be used for the
straight line path.

Programming
ANG= ;; angle value for defining a straight line

C93
Section 2
Notes
Unconditional program jumps

Function
NC programs process their blocks in the sequence in which they
were written.
The jump destination can be a block with a label or with a block num-
ber. The block must be located within the program.

Program
GOTOF label ;; jump forward to label
GOTOB label ;; jump backwards to label

Conditional program jumps

Function
Jump conditions are formulated after the if instruction. If the jump
condition (value not zero) is satisfied, the jump takes place.

Program
IF condition GOTOF label ;; jump forward to label
IF condition GOTOB label ;; jump backwards to label
N10 IF R1==1 GOTOF LABEL1

«
N90 LABEL1:
N100 IF R1>1 GOTOF LABEL2
«
N150 LABEL2:
«
N800 LABEL3:
«
N1000 IF R45==R7+1 GOTOB LABEL3
C93
Notes
Milling on Turning Machines

Milling on front face - TRANSMIT
This function is only available for SINUMERIK 802D sl plus and pro.

Function
This transformation function TRANSMIT allows convenient
programming of milling/drilling on the front face of turned parts.
A Cartesian coordinate system is used to program these machining
operations.
The control transforms the programmed traversing movements of the
Cartesian coordinate system into traversing movements of the real
machine axes. The main spindle functions here as the machine
rotary axis.
In addition to the tool length offset, it is also possible to work with the
tool radius offset (G41, G42).
The velocity control makes allowance for the limits defined for the
rotations.

Programming
TRANSMIT ;; activate TRANSMIT (separate block)
TRAFOOF ;; deactivate (separate block)

C93
Notes
Milling on peripheral surface - TRACYL

Function
This transformation function TRACYL allows convenient program-
ming for milling on the peripheral surface of turned parts.
The path of the grooves is programmed in the plane peripheral sur-
face, which was logically developed for a specific machining
cylinder diameter.
The control transforms the programmed traversing movements in the
Cartesian coordinate X, Y, Z system into traversing movements of
the real machine axes. The main spindle functions here as the ma-
chine rotary axis.

Programming
TRACYL ;; activate TRACYL (separate block)
C93
Notes
This is a typical Turning program used on a turning machine, using most
additional G functions.
TOP:
G00 G90 G95 G40 G18 G70
IF R1==2 GOTOF END
LIMS=2500
G54
T1 D1
SETMS
G96 S990 M03 M08
G00 X4.0157 Z0.0078
G01 X-0.0787 F0.0078
G00 Z0.0787
X4.0157
CYCLE95( "AAA:AAA_E", 0.13770, 0.00390, 0.00390, 0.00390, 0.01370,
0.01390, 0.00390, 9, , ,0.01960)
G00 G40 X6.0 Z6.0 M05
T2 D1
SETMS
SPOS=0
SETMS(2)
G94 S800 F6 M03 M08
DIAMOF
TRANSMIT
G00 G17 G54 X1.1160 Y0.0 Z0.3937
MCALL CYCLE82( 0.39370, 0.00000, 0.07870, -0.39370, 0.00000,
0.00390)
HOLES2( 0.00000, 0.00000, 0.98420, 0.00000, 90.00000, 3)
MCALL
M05
TRAFOOF
DIAMON
G00 G40 X6.0 Z6.0
R1=R1+1
GOTOB TOP
END:
M30
;;*************CONTOUR************
AAA:
X1.5748 Z0.0787
Z0.0
X3.5433 ANG=100
Z-0.7874 RND=0.1968
X3.9370
Z-0.9842
X4.0157
M02
AAA_E:;;************* CONTOUR ENDS ************
C93
Notes
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SURJUDPLVUXQLQ³6LPXODWLRQ´
C93

Notes
C93

C94 Additional G functions - Milling
1 Brief description
Module objective:

Upon completion of this module you will understand commonly used additional used G functions (G-
Codes) in detail.

Module description:

We use G functions to instruct a machine what to do, but a structure should be kept to.

Module content:
Additional G functions in more detail

Example program

Additional G functions
in more detail
Section 2
Example program
Section 3
C94
Section 2
Notes
Rounding, chamfer - RND, CHF, CHR

Function
You can insert a chamfer (CHF of CHR) or rounding (RND) elements
into a contour intersection.

Programming
CHF= ;; insert chamfer, value is length of chamfer
CHR= ;; insert chamfer, value is side length of chamfer
RND= ;; insert rounding, value is radius of rounding

²²²²²²²²²²²²²²²²²²²²²²²²²²²²²²²²²
Angle - ANG

Function
If only one of the end points is known for a straight line, and an angu-
lar dimension is given on the drawing, this can be used for the
straight line path.

Programming
ANG= ;; angle value for defining a straight line

C94
Section 2
Notes
Unconditional program jumps

Function
NC programs process their blocks in the sequence in which they
were written.

Program
GOTOF label ;; jump forward to label
GOTOB label ;; jump backwards to label

²²²²²²²²²²²²²²²²²²²²²²²²²²²²²²²²²
Conditional program jumps

Function
Jump conditions are formulated after the if instruction. If the jump
condition (value not zero) is satisfied, the jump takes place.

Program
IF condition GOTOF label ;; jump forward to label
IF condition GOTOB label ;; jump backwards to label
N10 IF R1==1 GOTOF LABEL1

«
N90 LABEL1:
N100 IF R1>1 GOTOF LABEL2
«
N150 LABEL2:
«
N800 LABEL3:
«
N1000 IF R45==R7+1 GOTOB LABEL3
C94
Notes
Milling on peripheral surface - TRACYL

Function
This transformation function TRACYL allows convenient program-
ming for milling on the peripheral surface of cylindrical parts.
The path of the grooves is programmed in the plane peripheral sur-
face, which was logically developed for a specific machining
cylinder diameter.
The control transforms the programmed traversing movements in the
Cartesian coordinate X, Y, Z system into traversing movements of
the real machine axes. A rotary axis (rotary table) is required.

Programming
TRACYL ;; activate TRACYL (separate block)
C94
Notes
This is a typical Mill program used on a turning machine, using most addi-
tional G functions.
TOP:
G00 G90 G95 G40 G17 G70
IF R1==2 GOTOF END
T1
M6
G94 S424 F10.5 M03 M08
G90 G54 G0 X-1.3779 Y2.3622
G0 Z0.0800
G1 Z0
X4.0
Y0.8
X-1.3779
G0 Y-1.3779
G1 Z-0.3937 F40
G41 X0.1968
Y2.7559 RND=0.3937 F10.5
X2.8346 Y2.7559
X3.6220 Y2.2835
Y0.3937 CHF=0.0800
X0.1771
G40 Y-0.8267
G0 Z0.0800
Z4.0
T2
M6
G94 S800 F6 M03 M08
G00 G54 X1.0 Y0.0 Z2.0
Z0.3937
MCALL CYCLE82( 0.39370, 0.00000, 0.08000, -0.39370, 0.00000,
0.00400)
HOLES2( 0.00000, 0.00000, 1.00000, 0.00000, 90.00000, 3)
MCALL
G00 G40 X6.0 Y6.0 Z6.0
R1=R1+1
GOTOB TOP
END:
M30

C94
Notes
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C94

C77 Creation of a Milling program
1 Brief description
Module objective:

Upon completion of this module you can create a milling program.
Module description:

This module describes how to write a part program for a milling machine, by example.
Module content:
Creating a work plan

Creating a list of tools
Define the program structure
Create example program in editor
Simulate the program

Creating a work plan

Section 2
Creating a list of tools

Section 3
Define the program

Section 4
structure
Create example pro- Section 5

gram in editor

Section 6
C77
Section 2 Creating a work plan
Notes
An example program will be created using the following workpiece:
The work plan is used to define the steps which have to be carried
out to machine the workpiece.

Working Step Nr. Operation Tools
1 Surface milling (QGPLOO'³

2 Contour milling (QGPLOO'³
3 Slot milling 6ORWPLOO'³
C77
Section 3 Creating a list of tools
Notes
The tool list contains the technology information for each tool. This infor-
mation will be used in the NC program, for the respective tool.
The speeds and feeds have to be adapted dependant upon the workpiece
material.
Spindle
Tool / Feed Speed
T-Nr. direction Coolant
Operation inch/min rpm
M3/M4
(QGPLOO'³
Surface milling 1 ³ 424 M3 x
(QGPLOO'³
Contour milling 1 ³ 424 M3 x
6ORWPLOO'³
2 ³ 4200 M3 x
Slot milling
C77
Section 4 Define the program structure
Notes
The program sequence can be created from the work plan.
7RRO(QGPLOO'³

Change tool
Select the origin (absolute/incremental)
Activate zero offset
Define the work plane
Program spindle speed and direction
Program feedrate
Switch coolant on
Surface milling
Position on the outside contour
Contour milling
Retract tool
Stop spindle and coolant

7RRO6ORWPLOO'³

Change tool
Select the origin (absolute/incremental)
Define the working plane
Program spindle speed and direction
Program feedrate
Switch coolant on
Slot milling
Retract tool
Stop spindle and coolant
Return to home position
Program end

C77
Section 5 Create example program in editor
Notes
A new program has to be generated in order to insert the ISO code.
The program should be given the name PLATE1.
First a new directory called PLATE1 can to be generated.
Use the following sequence to complete this task.
Curser over new directory name.
Or with
A new program has to be generated in order to insert the code.
The program should be given the name PLATE1.
After generating a new program in the editor, the blocks for the surface
milling, contour milling and the slot milling have to be typed in.
C77
Notes
This is an example of the NC blocks that will machine the component.
G00 G90 G94 G40 G17 G70

T1 D1 ;;End Mill D2.3"
G94 S424 F10.6 M03 M08
G90 G54 G0 X-1.37 Y2.36 ;; Basic settings, Start point
G0 Z0.08
G1 Z0
X3.937
Y0.787
X-1.377
G0 Y-1.377
G1 Z-0.393 F40
G41 X0.196 ;; Start the radius compensation
Y2.755 RND=0.393 F10.6 ;; Corner above left
X2.83 Y2.755
X3.622 Y2.283 ;; Angle contour
Y0.393 RND=0.59 ;; Corner below right
X0.177 ;; End point 0.02" further
G40 Y-0.826 ;; Cancel radius compensation
G0 Z0.08
Z3.93
T2 D1 ;; Slot Mill D0.23"
G94 S4200 F6 M04 M08
G90 G54 G17 G0 X1.181 Y1.141
G0 Z0.08
G1 Z-0.196 ;; Infeed into slot
X2.755 F22.16
G0 Z0.08 ;; Bottom slot is finished
X2.755 Y2.401 ;; Start point top slot
G1 Z-0.196 F6 ;; Infeed top slot
X1.181 F22.16
G0 Z0.08 ;; Top slot finished
Z4 M5 M9 ;; Retract tool
X-8 Y6 ;; Home position
M30 ;; Program end
C77
Section 6 Simulate the program
Notes
The program can be tested in the Simulation mode.
The necessary tools have to exist in the tool list in order to simulate the
program.

This is the sequence to test the NC program in Simulation:
Once you have simulated the NC program you can use the EDIT softkey to
go back to the EDITOR and RESET button to eliminate any alarms.
C77

Notes
C77

C78 Creation of a Turning program
1 Brief description
Module objective:

Upon completion of this module you can create a turning program
Module description:

This module describes how to write a part program for a turning machine, by example.
Module content:
Create a work plan

Create a list of tools
Define the program structure
Create example program in editor

Create a work plan

Section 2
Create a list of tools

Section 3
Define the program

Section 4
structure
Create example pro- Section 5

gram in editor

Section 6
C78
Section 2 Create a work plan
Notes
Dia 1.88"
Dia 1.0"
0.08" x CHF
2.36"
The work plan is used to define the steps which have to be carried
out to produce the workpiece.
Working step Nr. Operation Tools

1 Rough turn Roughing tool
2 Finish turn Finishing tool
C78
Section 3 Create a list of tools
Notes
The tool list contains the technology information for each tool. This infor-
mation will be used in the NC program, for the respective tool.
The speeds and feeds have to be adapted dependant upon the workpiece
material.
Spindle
Tool / Feed Speed
T-Nr. direction Coolant
Operation inch/rev ft/min
M3/M4
Roughing tool
5³ 1 0.018 900 M3 x
Finishing tool
5³ 2 0.004 900 M3 x
C78
Section 4 Define the program structure
Notes
The program sequence can be created from the work plan.
7RRO5RXJKLQJWRRO5³

Select the origin (absolut/incremental)
Tool change
Program constant surface speed and spindle direction
Program feedrate
Switch coolant on
Face off
Position on the front face
Finish turn out side
Return to toolchange

7RRO)LQLVKLQJWRRO5³

Select the origin (absolut/incremental)
Tool change
Program constant surface speed and spindle direction
Program feedrate
Switch coolant on
Face off
Position on the front face
Finish turn out side
Return to toolchange
C78
Notes
A new program has to be generated in order to insert the ISO code.
The program should be given the name C78_TURN.
First a new directory called C78 can to be generated.
Use the following sequence to complete this task.
The new directory will be generated, and should be opened
Or with
The main program is generated.
After generating a new program in the editor, the NC blocks for the surface
milling, contour milling and the slot milling have to be typed in.
C78
Notes
This is an example of the NC blocks that will machine the component.
N10 G00 G90 G95 G40 G70 G18

N20 LIMS=3000
N30 G54
17'5RXJKWRRO5³
N50 G96 S900 M03 M08
N60 G00 X2.05 Z0.004
N70 G1 X-0.078 F0.018
N80 G00 Z0.078
N90 X1.65
N100 G01 Z0.004
N110 X1.740
N120 X1.9 Z-0.07
N130 Z-2.358
N140 X2.05
N150 G00 G40 X6.0 Z6.0
17')LQLVKWRRO5³
N170 G96 S900 M03 M08
N180 G00 X1.88 Z0.0
N190 G01 X-0.078 F0.004
N200 G00 Z0.078
N210 X1.65
N220 G01 Z0.0
N230 X1.88 CHR=0.08
N240 Z-2.36
N250 X2.05
N260 G00 G40 X6.0 Z6.0
N270 M30
C78
Section 6 Simulate the program
Notes
The program can be tested in the simulation mode.
The necessary tools have to exist in the tool list in order to simulate the
program.

This is the sequence to test the NC program in Simulation:
Once you have simulated the NC program you can use the EDIT softkey to
go back to the EDITOR and RESET button to eliminate any alarms.
C78

Notes
C78

C99 Cycles for Milling
1 Brief description
Module objective:
Upon completion of this module you will understand the basic principle and information required for
milling cycles.

Module description:
Cycles are generally technology subroutines that can be used to carry out a specific machining proc-
ess, such as drilling of a thread (tapping) or milling of a pocket. These cycles are adapted to individ-
ual tasks by parameter assignment.

Module content:
Graphical cycles support

Milling cycles
Drilling cycles

Graphical cycles
support
Section 2
Milling cycles
Section 3
Drilling cycles
Section 4
C99
Section 2 Graphical cycles support
Notes
Graphical cycle support in the program editor
The program editor in the control system provides you with programming
support to add cycle calls to the program and to enter parameters.
Function
The cycle support consists of three components:
Cycle selection
Input screenforms for parameter assignment
Help screen for each cycle (is to be found in the interactive screen-
form).
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2
1
1 From he horizontal keys you can choose from milling or drilling
cycles.
2 Once you have chosen milling or drilling cycles you can then use
the vertical keys for the different types of cycles within that group.
C99
Section 2 Graphical support cycles
Notes
Input screenforms for parameter assignment for Cycle 81 drilling.
3
3 Parameter assignments for the cycle
At any time you can press help the button which will give you an explana-
tion for each of the parameters required.
i
HELP
C99
Section 3 Milling cycles
Notes
You are given the task to face and machine the pocket on your work piece.
200.00
M10 x 20mm
120.00
200.00
120.00
Dia 80 x 15mm
We would create a basic program so that we can add the facing and
pocket cycles.

First of all we will create the basic start of the program.
C99
Notes
Then we will add the first milling cycle, as shown in the following
sequence.
4
4 Enter data taken from your drawing.
C99
Notes
Facing - CYCLE71

Programming
CYCLE71(RTP, RFP, SDIS, DP, DRP, DTB)

Parameters

_RTP retraction plane (absolute)
_RFP reference plane (absolute)
_SDIS safety plane (enter without sign)
_DP final drilling depth (absolute)
_PA starting point of 1st axis (plane you are working in)
_PO starting point of 2nd axis (plane you are working in)
_LENG length along 1st axis, incremental with sign from
start point
_WID length along 2nd axis, incremental with sign from
start point
_STA angle between longitudinal axis and the 1st axis of
the plane you are working in (enter without sign)

_MID maximum depth of cut (enter without sign)
_MIDA maximum width of cut by cutter
_FDP distance past end of material in direction of cut
_FALD maximum finish depth of cut (enter without sign)
_FFP1 feedrate for surface machining
_VARI machining type
UNITS value
1: roughing
2: finishing
TENS value
1: parallel to 1st axis, unidirectional
2: parallel to 2nd axis, unidirectional
3: parallel to 1st axis, changing direction
4: parallel to 2nd axis, changing direction

1 & 2 3 & 4

_FDP1 Distance of overhang by cutter along direction of
cut
C99
Notes
If you look below, as you cursor down the parameter windows you will get
a prompt with text, which relates to the given pictures.
You can also press

the online help button,
which will give you a
written explanation of
each of the parame-
ters.
i
HELP
C99
Notes
Your program should now look as above.

We have now created a program to face off the component.
See if you can now create the rest of the program to machine the pocket.
C99
Notes
To create the rest of the program, you will have to use POCKET4 (Circular
Pocket).
Final program and simulation.
C99
Notes
C99
Section 4 Drilling cycles
Notes
You are given the task to drill and tap 4 holes in your work piece.

200.00
M10 x 20mm
120.00
200.00
120.00
Dia 80 x 15mm
We would create a basic program to CENTER DRILL, DRILL and TAP.

C99
Notes
Then we will add the first drilling cycle, as shown in the following
sequence.
5
5 Enter data taken from your drawing.
C99
Notes
Make the drilling cycle MODAL using the following sequence.
6
6 Note the MCALL in red text.
C99
Notes
Drilling, centering - CYCLE82

Programming

Parameters

RTP retraction plane (absolute)
RFP reference plane (absolute)
SDIS safety plane (enter without sign)
DP final drilling depth (absolute)
DPR final drilling depth relative to the reference plane
(enter without sign)
DTB dwell time at final depth (chip breaking)

These six parameters are used through out all the drilling cycles, but as
more functionality is required as are the number of parameters increased.

a prompt with text, which relates to the picture guide.
C99
Notes
We then add the positions of the 4 holes.
7
7 Enter data taken from your drawing
C99
Notes
8
8 Because the drilling cycle was a modal call, you have to deacti-
vate the call
C99
Notes

We have now created a program to center drill 4 holes.
See if you can now create the rest of the program to drill and tap the 4
holes.
C99
Notes
To create the rest of the program, you will have to use CYCLE81 and CY-
CLE84 and HOLES2, remembering to make the correct CYCLES modal
and non-modal.
Final program. For Centre Drill, Drill and Tap.
C99
Notes
If you now put both parts of the programs together, then you would have a
program that would FACE, machine POCKET, CENTER DRILL, DRILL
and TAP your component.

G00 G90 G94 G40 G70 G17

T1
M6
G95 S1500 F0.009 M03 M08
G00 G54 X2.3622 Y0.0 Z2.0
CYCLE71( 1.96850, 0.01960, 0.07870, 0.00000, -3.93700, -3.93700,
7.87400, 7.87400, 0.00000, 0.09840, 1.57480, 0.15740, 0.00000, 0.00390,
12, 0.15740)
G00 G40 Z4.0
T3
M6
G95 S2500 F0.0098 M03 M08
G00 G54 X0.0 Y0.0 Z2.0
POCKET4( 1.96850, 0.00000, 0.07870, -0.59050, 1.57480, 0.00000,
0.00000, 0.09840, 0.00390, 0.00190, 19.50000, 9.84000, 3, 12, 0.23620,
0.00000, 0.00000, 0.39370, 0.39300)
G00 G40 Z8.0
T4
M6
G95 S1500 F0.009 M03 M08
G00 G54 X2.3622 Y0.0 Z2.0
MCALL CYCLE82( 1.96850, 0.00000, 0.07870, -0.20660, 0.00000,
0.10000)
HOLES2( 0.00000, 0.00000, 2.36220, 0.00000, 90.00000, 4)
MCALL
G00 G40 Z4.0
T5
M6
G95 S800 F0.0078 M03 M08
G00 G54 X2.3622 Y0.0 Z2.0
MCALL CYCLE81( 1.96850, 0.00000, 0.07870, -1.18110, 0.00000)
HOLES2( 0.00000, 0.00000, 2.36220, 0.00000, 90.00000, 4)
G00 G40 Z4.0
T6
M6
G95 S800 F0.0078 M03 M08
G00 X2.3622 Y0.0 Z2.0
MCALL CYCLE84( 1.96850, 0.00000, 0.07870, -0.70860, 0.00000,
0.10000, 3, 10.00000, , ,800.00000, 800.00000)
HOLES2( 0.00000, 0.00000, 2.36220, 0.00000, 90.00000, 4)
MCALL
G00 G40 X0.0 Y6.0 Z8.0
M30
C99

Notes
C99

C100 Cycles for turning
1 Brief description
Module objective:
Upon completion of this module you will understand the basic principle and information required for
turning cycles.

Module description:
Cycles are generally technology subroutines that can be used to carry out a specific machining proc-
ess, such as turning of a contour or drilling. These cycles are adapted to individual tasks by parame-
ter assignment.

Module content:
Graphical cycle support

Turning cycles
Drilling cycles

Graphical cycle
support
Section 2
Turning cycles
Section 3
Drilling cycles
Section 4
C100
Section 2 Graphical cycle support
Notes
Graphical cycle support in the program editor

The program editor in the control system provides you with programming
support to add cycle calls to the program and to enter parameters from
your drawing.
Function
The cycle support consists of three components:
Cycle selection
Input screenforms for parameter assignment
Help screen for each cycle (is to be found in the interactive screen-
form).
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2
1
1 From he horizontal keys you can choose from turning or drilling
cycles.
2 Once you have chosen turning or drilling cycles you can then use
the vertical keys for the different types of cycles within that group.
C100
Section 2 Graphical support cycles
Notes
Input screenforms for parameter assignment for Cycle 95 Stock removal.
3
3 Parameter assignments for the cycle
At any time you can press the help button which will give you an explana-
tion for each of the parameters required.
i
HELP
C100
Section 3 Turning cycles
Notes
C100
Notes
You are given the task to rough face and rough turn .

´
´
´ ´
5´ ´
´

5

5´
´
´
´
5

´
´
´

5´
´ ´
We would create a basic program that will face the component and then
add the rough turning cycle.

First of all we will create the basic start of the program, as shown below.
C100
Notes
Then we will add the stock removal cycle, as shown in the following
sequence.
The most commonly used turning cycle, is the stock removal cycle. But for
this cycle to work correctly we must tell the cycle what the geometry de-
scription of the turned part is.
There are two methods to use.
1. Contour description is stored as a sub program
2. Contour description is stored at the bottom of the main
program, after the M30 code.

C100
Notes
Method 1. Creating a sub program with geometry description
3
3 Type in the name of the contour so that you recognize the name
for future reference, followed by:
4
4 Followed by the softkey:
C100
Notes
5
5 The control automatically creates a sub program with the name

that you have entered in NPP, with the cursor above the M02
code.
In the sub program, we define the contour description of the finished part,
as a single pass.

We must start the contour with an X and Z coordinate.
N10 G01 X0.0 Z0.0

N20 G03 X0.787 Z-0.05 I0 K-1.575 RND=0.078
N30 G01 Z-0.401 RND=0.197
N40 X1.417 Z-0.548
N50 Z-0.984
N60 G02 X1.417 Z-1.378 CR=0.512
N70 G01 Z-1.574
N80 X1.574
Now you can enter the values into the contour sub program.
C100
Notes
6
6 Once you have entered the description of the contour, use the
following sequence to continue.
C100
Notes
7
7 This is the minimum data to be entered for the stock removal
cycle, this can be taken from the drawing. To continue with the
following sequence.
8
8 Note Position of the cursor ready for you to continue typing the
rest of the program.
C100
All data must now be entered, as how to machine the workpiece to the Notes
contour.
Cutting with relief cut - CYCLE95

Programming

CYCLE95(NPP,MID,FALZ,FALX,FAL,FF1,FF2,FF3,VARI,DT,DAM,_VRT)

Parameters

NPP name of contour
MID in feed depth of cut
FALZ allowance left on contour for finishing (Z axis)
FALX allowance left on contour for finishing (X axis)

FAL allowance left on contour profile
FF1 feedrate for roughing without undercut
FF2 feedrate for inserting into relief cut
FF3 feedrate for finishing
VARI machining type
Type 1-4 roughing cycles
Type 5-8 finishing cycles
Type 9-12 complete machine cycles

DT dwell time for chip breaking when roughing
DAM path length after which each roughing step is
interrupted for chip breaking

_VRT retraction distance from contour when roughing
C100
Notes

C100
Notes
If you run simulation using the following sequence this is what is shown.
When you have finished use this sequence to show the NC
program in the Editor.
If you look in program manager you will see the sub program
CONTOUR.SPF
9
9 This screen shows the sub program that is being used by the
main program.
C100
Notes
Method 2. Creating a program including geometry
10
10 Type in the name of the contour so that you recognize the name
for future reference, followed by:
11
11 Followed by the softkey:
C100
Notes
The control now creates an area at the bottom of your program to type
your geometry description: Note were the cursor is placed.
12
12 The control automatically creates a description of the contour at

the bottom of the NC program using the name given in NPP.
At the bottom of your program, we define the contour description of the
finished part, as a single pass.

We must start the contour with an X and Z coordinate.

N10 G01 X0.0 Z0.0

N20 G03 X0.787 Z-0.05 I0 K-1.575 RND=0.078
N30 G01 Z-0.401 RND=0.197
N40 X1.417 Z-0.548
N50 Z-0.984
N60 G02 X1.417 Z-1.378 CR=0.512
N70 G01 Z-1.574
N80 X1.574
C100
Notes
13
13 Once you have entered the description of the contour, use the
following sequence to continue.
All data must now be entered, as how to machine the workpiece to the
contour.
14
14 Note the name of the contour.
C100
Notes
15
15 This is the minimum data to be entered for the stock removal
cycle, this can be taken from the drawing. To continue with the
following sequence.
Note position of the cursor ready for you to continue typing the rest of the
program.
C100
Notes
If you look in program manager you will see the sub program
CONTOUR.SPF
16
16 This screen shows that there is no sub program that is being
used by the main program.
C100
Notes
To add a finishing tool to the program, first add the tool change position to
end of the program to the roughing tool.
G00 G40 X6.0 Z6.0
Then add the basic start program for the finishing tool including the finish
facing off.
T2 D1
G96 S750 M03 M08
G00 X1.65 Z0.08
Then follow this sequence.
When entering the cycle data for the finish tool you only have to enter
three bits of data. Contour name, Finish feedrate, and type of operation
C100
Notes
To add a grooving tool to the program, first add the tool change position to
end of the program to the roughing tool.
G00 G40 X6.0 Z6.0
Then add the basic start program for the grooving tool .
T3 D1
G96 S300 M03 M08
G00 X1.574 Z0.0
Enter the cycle data required from data from the drawing.
C100
Notes
Groove ± CYCLE93

Programming

CYCLE93(SPD, SPL, WIDG, DIAG, STA1,ANG1,ANG2,RCO1,RCO2,
RCI1,RCI2,FAL1,FAL2, IDEP, DTB, VARI, _VRT)

Parameters

SPD Starting point in the transverse axis
SPL Starting point in the longitudinal axis
WIDG Groove width (enter without sign)
DIAG Groove depth (enter without sign)

STA1 Angle between contour and longitudinal
ANG1 Flank angle 1: on the groove side determined point
ANG2 Flank angle 2: on the other side
RCO1 Radius/chamfer 1, externally: on the starting point
RCO2 Radius/chamfer 2, externally
RCI1 Radius/chamfer 1, internally: on the starting point
RCI2 Radius/chamfer 2, internally

FAL1 Finishing allowance at the recess base
FAL2 Finishing allowance at the flanks
IDEP Infeed depth (enter without sign)
DTB Dwell time at recess base
VARI Machining type
Range of values: 1...8 and 11...18
_VRT retraction distance
C100
Notes
C100
Notes
C100
Notes
Your completed program with ROUGH, FINISH turn and GROOVE are
shown below:
G00 G90 G95 G40 G18 G70

LIMS=2500
G54
T1 D1
G96 S750 M03 M08
G00 X1.65 Z0.004
G01 X-0.078 F0.013
G00 Z0.078
X1.65
CYCLE95( "CONTOUR:CONTOUR_E", 0.098000, 0.002000,
0.004000, 0.004000, 0.009000, 0.006000, ,1, , ,0.039000)
G00 G40 X6.0 Z6.0
T2 D1
G96 S750 M03 M08
G00 X1.65 Z0.08
CYCLE95( "CONTOUR:CONTOUR_E", , , , , , ,0.004000, 5, , ,)
G00 G40 X6.0 Z6.0
T3 D1
G96 S300 M03 M08
G00 X1.574 Z0.0
CYCLE93( 1.417000, -0.629000, 0.197000, 0.236000, 0.000000,
0.000000, 0.000000, 0.039000, 0.039000, 0.000000, 0.000000,
0.002000, 0.004000, 0.118000, 0.078000, 5)
G00 G40 X6.0 Z6.0
M30
;;*************CONTOUR************
CONTOUR:
N10 G01 X0.0 Z0.0
N20 G03 X0.787 Z-0.05 I0 K-1.575 RND=0.078
N30 G01 Z-0.401 RND=0.197
N40 X1.417 Z-0.548
N50 Z-0.984
N60 G02 X1.417 Z-1.378 CR=0.512
N70 G01 Z-1.574
N80 X1.574
CONTOUR_E:;;************* CONTOUR ENDS ************
C100
Notes
The three remaining cycles are for UNDERCUTTING, THREAD UNDER-
CUTTING, and THREADING.
They all require data that is taken from the component drawing.
C100
Notes
Undercut (forms E and F to DIN) ± CYCLE94

Programming

CYCLE94(SPD, SPL, FORM, VARI)

Parameters

SPD Starting point in the transversal axis
SPL Starting point of the tool compensation
FORM Definition of the form
Values: E (for form E)
F (for form F)
VARI Determination of type of the machining for the
Range of values: 1 ... 4
C100
Notes
Thread undercut ± CYCLE96

Programming

CYCLE96 (DIATH, SPL, FORM, VARI)

Parameters

DIATH Nominal diameter of the thread
SPL Starting point of the correction in the longitudinal
axis
FORM Definition of the form
Values: A (for form A)
B (for form B)
C (for form C)
D (for form D)
C100
Notes
Thread cutting ± CYCLE97

Programming

CYCLE97(PIT, MPIT, SPL, FPL, DM1, DM2, APP, ROP, TDEP, FAL,
IANG,NSP,NRC,NID,VARI, NUMT, _VRT)

Parameters

PIT Thread pitch as a value (enter without sign)
MPIT Thread pitch as a thread size
Range of values: 3 (for M3) ... 60 (for M60)

SPL Thread starting point in the longitudinal axis
FPL Thread end point in the longitudinal axis
DM1 Thread diameter at the starting point
DM2 Thread diameter at the end point
APP Run-in path (enter without sign)
ROP Run-out path (enter without sign)
TDEP Thread depth (enter without sign)
FAL Finishing allowance (enter without sign)
IANG Infeed angle
5DQJHRIYDOXHV³ÍRUIODQNLQIHHGDWWKHIODQN
³±ÍRUDOWHUQDWLQJIODQNLQIHHG
NSP Starting point offset for the first thread turn
NRC Number of roughing cuts (enter without sign)
NID Number of idle passes (enter without sign)
NUMT Number of thread turns (enter without sign)
_VRT retraction distance
C100
Notes
You are given the task to drill and tap a hole in your work piece.

M10 x 0.787"
We would create a basic program to DRILL, and TAP.

C100
Notes
Then we will add the drilling cycle, as shown in the following sequence.
17
17 This is the data to be entered for the drill cycle, this can be taken
from the drawing. To continue with the following sequence.
C100
Notes
Drilling , centering - CYCLE82

Programming

Parameters

RTP retraction plane (absolute)
RFP reference plane (absolute)
SDIS safety plane (enter without sign)
DP final drilling depth (absolute)
DPR final drilling depth relative to the reference plane
(enter without sign)
DTB dwell time at final depth (chip breaking)

These six parameters are used through out all the drilling cycles, but as
more functionality is required as are the number of parameters increased.

C100
Notes

We have now created a program to drill the hole.
To check the program follow this sequence.
This allows the simulation to show the correct working plane for drilling.
C100
Notes
See if you can now create the rest of the program to tap the hole.
To create the rest of the program, you will have to use cycle84.
C100
Notes
Final program: For Drilling and Tapping.
G00 G90 G95 G40 G17 G70

LIMS=2500
G54
T6 D1
G95 S800 F0.01 M03 M08
G00 X0.0 Z0.078
CYCLE82( 0.078000, 0.000000, 0.078000, -0.894000, 0.000000,
0.500000)
G00 G40 X6.0 Z6.0
T7 D1
G95 S800 M03 M08
G00 X0.0 Z-0.196
CYCLE84( 0.196000, 0.000000, 0.078000, -0.787000, 0.000000,
0.100000, 3, 10.000000, , ,800.000000, 800.000000)
G00 G40 X6.0 Z6.0
M30
C100

C105 Free Contour Programming - Turning
1. Description
Module objective:

Upon completion of this module you use Free Contour Programming, by example.
Module description:

Free contour programming is a support tool for the editor. The contour programming function enables
you to create simple and complex contours.

Module content:
Free Contour Programming Features

Free Contour Programming by Example
Free Contour
Programming features
Section 2
Free Contour
Programming by Section 3
Example
Section 2 Free Contour Programming Features
Notes
Functionality

Free contour programming is a support tool for the editor. The contour pro-
gramming function enables you to create simple and complex contours.
An integrated contour calculator (geometry processor) calculates any
missing parameters for you, provided that they can be calculated from
other parameters. You can link together contour elements. Contour transi-
WLRQHOHPHQWV³UDGLXV´DQG³FKDPIHU´DUHDOVRSURYLGHG
The programmed contours are transferred to the edited part program.
Contour elements

The following are contour elements:

Start point
Straight line in the vertical direction
Straight line horizontal in the direction
Oblique straight line
Circular arc
Notes
Define a start point

When entering a contour, begin at a position which you already know and
enter it as the starting point. The sequence of operations for defining the
start point of a contour is as follows.

You have opened a part program and selected soft key
³&RQWRXU´WRSURJUDPDQHZFRQWRXU7KHLQSXWVFUHHQIRU
specifying the start of the contour is displayed as below:

1
1 $V\RXFXUVRUGRZQWKH³VWDUWSRLQWÍLHOGWKH\ZLOOEHKLJKOLJKWHG
in a dark brown field.
Notes
Soft keys and parameters.

Once you have defined the contour start point, you can begin program-
ming the individual contour elements from the main screen below:
Vertical soft keys

The following contour elements are available for programming contours:

Straight line in the vertical direction.

Straight line in the horizontal direction.

Oblique line in the X/Y direction. Enter the end point of
the line using coordinates or an angle.

Arc with any direction of rotation.

7KH³&RQWLQXH´VRIWNH\DFFHVVHVWKH³3ROH´VXEVFUHHQ
softkey.

%\VHOHFWLQJWKH³&DQFHO´VRIWNH\\RXFDQUHWXUQWRWKH
main screen without transferring the last edited values.

:KHQ\RXVHOHFW³$FFHSW´VRIWNH\\RXFORVHWKHFRQWRXU
screen and return to the program editor.
Notes
Horizontal soft keys

You can zoom in and out of the graphic with the first four
horizontal soft keys.

When you select this soft key, you can move the red
cross-hair with cursor keys and choose a picture detail to
display.

If you press this soft key, help graphics are displayed in
addition to the relevant parameter information (as seen
below). Press the soft key again to exit help mode.
Notes
Parameter description of straight line /circle contour elements

3DUDPHWHUVIRUFRQWRXUHOHPHQW³6WUDLJKWOLQH´
Parameter &RQWRXUHOHPHQW³6WUDLJKWOLQH´
X inc Incremental end position in X direction
X abs Absolute end position in X direction
Z inc Incremental end position in Z direction
Z abs Absolute end position in Z direction
L Length of straight line
Į1 Pitch angle with reference to X axis
Į2 Angle to preceding element;; tangential transi-
tion: Į2=0
Transition to next element Transition element to next contour is a
chamfer (FS)
Transition element to next contour is a
radius .
FS=0 or R=0 means no transition element
Notes
3DUDPHWHUVIRUFRQWRXUHOHPHQW³&LUFOH$UF´
Parameter &RQWRXUHOHPHQW³&LUFOH$UF´
Direction of rotation In clockwise or counter-clockwise direction
R Radius of circle

Z inc Incremental end position in Z direction
Z abs Absolute end position in Z direction
I Position of circle center point in X direction
(abs. or incr.)
K Position of circle center point in Z direction
(abs. or incr.)

tion: Į2=0
ß1 End angle with reference to X axis
ß2 Angle of aperture of circle
chamfer (FS)
radius .
Notes
Additional soft keys

6HOHFWWKH³$OOSDUDPHWHUV´VRIWNH\WRGLVSOD\DVH
lection list of all the parameters for the contour ele-
ment.
If you leave any parameter input fields blank, the
control assumes that you do not know the correct
value and attempts to calculate them from the
values of the other parameters.

7KH³$OWHUQDWLYH´VRIWNH\LVGLVSOD\HGRQO\LQFDVHV
where the cursor is positioned on an input field with
several switchover settings.

Some parameter configurations can produce sev-
eral different contour lines. In such cases, you will
EHDVNHGWRVHOHFWDGLDORJ%\SUHVVLQJWKH³'LDORJ
VHOHFW´VRIWNH\\RXFDQVHOHFWWKHDYDLODEOHRSWLRQ
in the graphic display area.

6HOHFWWKH³'LDORJDFFHSW´VRIWNH\WRFRQIRUP\RXU
choice of available contours (see above).

Section 3 Free Contour Programming by example
Notes
Create the start of the program as shown below.
Notes
Follow the sequence to create the contour for the stock removal cycle.
2
2 Enter name of contour (NPP)
Notes
To program the contour follow this sequence.
The first element that must be entered is the start point.
Notes
Now follow the next 8 elements:
Notes
Notes
Notes
Notes
Use the following sequence to enter the contour definition into the NC
program.
Notes
Enter data into the stock removal parameter mask
Notes
Check the program using Simulation.

C106 Free Contour Programming - Milling
1. Description
Module objective:

Upon completion of this module you can use Free Contour Programming, by example.
Module description:

Free contour programming is a support tool for the editor. The contour programming function enables
you to create simple and complex contours.

Module content:
Free Contour Programming Features

Free Contour Programming by Example
Free Contour
Programming features
Section 2
Free Contour
Programming by Section 3
Example
Notes
Functionality

Free contour programming is a support tool for the editor. The contour pro-
gramming function enables you to create simple and complex contours.
An integrated contour calculator (geometry processor) calculates any
missing parameters for you, provided that they can be calculated from
other parameters. You can link together contour elements. Contour transi-
WLRQHOHPHQWV³UDGLXV´DQG³FKDPIHU´DUHDOVRSURYLGHG
The programmed contours are transferred to the edited part program.
Contour elements

The following are contour elements:

Start point
Straight line in the horizontal direction
Straight line in the vertical direction
Oblique straight line
Circular arc
Notes
Define a start point

When entering a contour, begin at a position which you already know and
enter it as the starting point. The sequence of operations for defining the
start point of a contour is as follows.

You have opened a part program and selected soft key
³&RQWRXU´WRSURJUDPDQHZFRQWRXU7KHLQSXWVFUHHQIRU
specifying the start of the contour is displayed as below:

1
1 $V\RXFXUVRUGRZQWKH³VWDUWSRLQWÍLHOGWKH\ZLOOEHKLJKOLJKWHG
in a dark brown field.
Notes
Soft keys and parameters.

Once you have defined the contour start point, you can begin program-
ming the individual contour elements from the main screen below:
Vertical soft keys

The following contour elements are available for programming contours:

Straight line in the vertical direction.

Straight line in the horizontal direction.

Oblique line in the X/Y direction. Enter the end point of
the line using coordinates or an angle.

Arc with any direction of rotation.

7KH³&RQWLQXH´VRIWNH\DFFHVVHVWKH³3ROH´VXEVFUHHQ
softkey.

%\VHOHFWLQJWKH³&DQFHO´VRIWNH\\RXFDQUHWXUQWRWKH
main screen without transferring the last edited values.

:KHQ\RXVHOHFW³$FFHSW´VRIWNH\\RXFORVHWKHFRQWRXU
screen and return to the program editor.
Notes
Horizontal soft keys

You can zoom in and out of the graphic with the first four
horizontal soft keys.

When you select this soft key, you can move the red
cross-hair with cursor keys and choose a picture detail to
display.

If you press this soft key, help graphics are displayed in
addition to the relevant parameter information (as seen
below). Press the soft key again to exit help mode.
Notes
Parameter description of straight line /circle contour elements

3DUDPHWHUVIRUFRQWRXUHOHPHQW³6WUDLJKWOLQH´
Parameter &RQWRXUHOHPHQW³6WUDLJKWOLQH´
Y inc Incremental end position in Y direction
Y abs Absolute end position in Y direction
tion: Į2=0
chamfer (FS)
radius .
Notes
3DUDPHWHUVIRUFRQWRXUHOHPHQW³&LUFOH$UF´
Parameter &RQWRXUHOHPHQW³&LUFOH$UF´
Direction of rotation In clockwise or counter-clockwise direction
R Radius of circle

Y inc Incremental end position in Y direction
Y abs Absolute end position in Y direction
I Position of circle center point in X direction
(abs. or incr.)
J Position of circle center point in Y direction
(abs. or incr.)

tion: Į2=0
ß1 End angle with reference to X axis
ß2 Angle of aperture of circle
chamfer (FS)
radius .
Notes
Additional soft keys

6HOHFWWKH³$OOSDUDPHWHUV´VRIWNH\WRGLVSOD\DVH
lection list of all the parameters for the contour ele-
ment.
If you leave any parameter input fields blank, the
control assumes that you do not know the correct
value and attempts to calculate them from the vales
of the other parameters.

7KH³$OWHUQDWLYH´VRIWNH\LVGLVSOD\HGRQO\LQFDVHV
where the cursor is positioned on an input field with
several switchover settings.

Some parameter configurations can produce sev-
eral different contour lines. In such cases, you will
EHDVNHGWRVHOHFWDGLDORJ%\SUHVVLQJWKH³'LDORJ
VHOHFW´VRIWNH\\RXFDQVHOHFWWKHDYDLODEOHRSWLRQ
in the graphic display area.

6HOHFWWKH³'LDORJDFFHSW´VRIWNH\WRFRQIRUP\RXU
choice of available contours (see above).

Notes
Create the start of the program as shown below.
Notes
To program the contour follow this sequence.
The first element that must be entered is the start point.
Notes
Now follow the next 6 elements:
Notes
Notes
Notes
Use the following sequence to enter the contour definition into the NC
program.
Notes
Add the end of the program.
Check the program using Simulation.

Notes

C59 Working with CF cards
1 Brief description
Module objective:

Upon completion of this module you can copy and paste programs between the CF card and the
CNC controller.
Module description:

It is possible to use a CF (Compact Flash) card in the controller as additional storage for part pro-
grams or for storing backups of the machines commissioning data. This module describes the usage
of the card in the control.
Module content:
Copying data to and from the card

Copying data to and

from the card Section 2
Section 2 Copying data to and from the card
2.1 Copying data to and from the card Notes
All data can be saved to a CF card using copy and paste functionality. To
use the feature a CF card should be inserted into the controller, as can be
seen below:

'DWDFDQEHWUDQVIHUUHGWRWKHFDUGLQWKH³3URJUDP0DQDJHU´DUHDRIWKH
FRQWURODOVRLQWKH³6\VWHPDUHD´

Keyboard (upright)
Keyboard (broad)
Program Manager
File functions
CF Card
Section 2 Copying data to and from the card
Notes
To copy data to the card in the program manager perform the following,
reverse the process to copy from card to NC.

Highlight the file

which should be
copied
With the COPY

softkey, the file is
copied to the buffer
of the control.
With paste the file

is copied to the
destination.


C82 Axis control / Jog - Turning
1 Brief description
Module objective:

Upon completion of this module you can jog all axis within the confines of the machine, using three
methods: Jog, Jog INC/VAR, Handwheel

Module description:

We use Axis Control/Jog to move axis, that we can setup tools, change tools / inserts, and gain
approved access to the workpiece.

Module content:
Jog
Jog INC/VAR
Handwheel
Jog
Section 2
Jog INC/VAR
Section 3
Handwheel
Section 4
C82
Section 2 Jog
Notes
To JOG the axis freely around within the confines of the machine, follow
this sequence.
1
1 In the STATUS area the control will show you that it is in JOG
mode
To Jog the axis use the push button for the required
axis and the direction to be moved:
If you use the rapid override button at the same time as the selected axis,
the axis will move at rapid speed until the buttons are released.
The use of the feed override switch allows you to
regulate the feed of the chosen axis.
C82
Section 3 Jog 1 INC
Notes
To INCREMENTALLY move the axis around within the confines of the
machine, follow this sequence.
2
2 In the STATUS area the control will show you what INC is being
used.
Depending on how many time you press the [VAR] button
Use the axis pushbutton for the required axis, and

direction to be moved. When pressed the chosen
axis will move by 1 increment per press.
C82
Section 3 Jog VAR
Notes
3
VAR mode.
Use the SETTINGS softkey to set the VARIABLE value
C82
Section 3 Jog VAR
Notes
Cursor down to VARIABLE INCREMENT using button.
C82
Section 3 Jog VAR
Notes
Enter the value for VAR INC

i.e. 0.5 increments

Type 500 using the numerical buttons

Followed by
4
4 The value that has been entered will be shown here.
1RWHWKHVWDWXVDUHDVKRZVWKDW³,QFUHPHQWDO9DULDEOH
´KDVQRZEHHQVHW
When you use the push buttons, the axis will JOG at 0.05 increment per press.
C82
Section 4 Hand wheel
Notes
To move the axis around within the confines of the machine, using the
hand wheel follow this sequence.
5
used.
C82
Notes
Using the soft keys
Select the axis you wish to move using the hand wheel

i.e. X axis
A tick box will now be shown by the side of the axis, in the hand wheel window.
C82
Notes
6
7
used.
7 In the Hand wheel area the control will show you which axis has
been selected.
When the hand wheel is used the X axis will move at 0.001mm per increment.
C82
Notes
8 To change the INCREMENT for the hand wheel, use the following button.
9 To change the axis use the soft keys.
8
9
C82
Section 4 Handwheel
Notes
You can use the hand wheel in MCS mode, which allows you to move the
axis with the figures on the screen relative to the machine and not the work
piece.

This will show the axis as X1
Z1

Use the following softkey.
C82

Notes
C82

C82 Axis control / Jog - Milling
1 Brief description
Module objective:

Upon completion of this module you can jog all axis within the confines of the machine, using three
methods: Jog, Jog INC/VAR, Handwheel

Module description:

We use Axis Control/Jog to move axis, that we can setup tools, change tools / inserts, and gain
approved access to the workpiece.

Module content:
Jog
Jog INC/VAR
Handwheel
Jog
Section 2
Jog INC/VAR
Section 3
Handwheel
Section 4
C82
Section 2 Jog
Notes
To JOG the axis freely around within the confines of the machine, follow
this sequence.
1
mode
To Jog the axis use the push button for the required
axis and the direction to be moved:
If you use the rapid override button at the same time as the selected axis,
the axis will move at rapid speed until the buttons are released.
The use of the feed override switch allows you to
regulate the feed of the chosen axis.
C82
Section 3 Jog 1 INC
Notes
2
used.
Use the axis pushbutton for the required axis, and

direction to be moved. When pressed the chosen
axis will move by 1 increment per press.
C82
Section 3 Jog VAR
Notes
3
VAR mode.
Use the SETTINGS softkey to set the VARIABLE value
C82
Section 3 Jog VAR
Notes
Cursor down to VARIABLE INCREMENT using button.
C82
Section 3 Jog VAR
Notes
Enter the value for VAR INC

i.e. 0.5 increments

Type 500 using the numerical buttons

Followed by
4
4 The value that has been entered will be shown here.
When you have entered the data in SETTINGS

press the soft key BACK.
When you use the push buttons, the axis will JOG at 0.05 increment per press.
C82
Notes
To move the axis around within the confines of the machine, using the
hand wheel follow this sequence.
5
used.
C82
Notes
Using the soft keys
Select the axis you wish to move using the hand wheel

i.e. X axis
A tick box will now be shown by the side of the axis, in the hand wheel window.
C82
Notes
6
7
used.
7 In the Hand wheel area the control will show you which axis has
been selected.
When the hand wheel is used the X axis will move at 0.001mm per increment.
C82
Notes
8 To change the INCREMENT for the hand wheel, use the following button.
9 To change the axis use the soft keys.
8
9
C82
Section 4 Handwheel
Notes
You can use the hand wheel in MCS mode, which allows you to move the
axis with the figures on the screen relative to the machine and not the work
piece.

This will show the axis as X1
Y1
Z1

Use the following softkey.
C82

Notes
C82

C75 MDA Mode - Turning
1 Brief description
Module objective:

Upon completion of this module you can execute commands in the MDA mode

Module description:

You can enter program commands in MDA and immediately execute them. This allows the operator
to activate functions on the machine normally for setting up purposes outside the NC program

Module content:
Functionality of MDA

Save MDA to program
Facing


Section 2
Save MDA to program

Section 3
Facing
Section 4
C75
Section 2 Functionality of MDA
Notes
The following functions are possible in MDA mode, executing immediately
program blocks in the machine area. It is possible to execute M functions,
especially for tool changing or activating clamping devices outside of the
NC program.

You can activate MDA in the following sequence:

To scratch on the workpiece (Set zero offset, or measure tools manually)
Jog and MDA can be used with each other.
In MDA you can then call the tool with spindle speed and direction, being
careful not to program M02 as this will have the effect of reseting the
given spindle speed and direction.
After NC start you can return to Jog mode and position the axis
accordingly.

Example shows text typed into the MDA area and sequence for moving
the axis:
T1 D1
G95 S200 M4
C75
Section 3 Save MDA to program
Notes
The content of the MDA buffer can be saved as an NC program, this can
later be used again.
Pre-conditions:
MDA-mode is active
Program blocks exist in the buffer.
To save MDA to a program select the following sequence:
1
2
1 ,QWKHZLQGRZ³6DYHDV³\RXFDQLQSXWWKHQDPHRIWKH
program in which the blocks will be saved.
2 The destination can be determined with the Select key (Drive
N:), the CF-card (Drive D:) or the RCS-connection can be selected.
The data will be saved with the following sequence:
C75
Section 4 Facing
Notes
With the facing function in MDA, the face or periphery of the workpiece can
be prepared for further operations.
The following example shows the sequence to perform this task:
The retract plane and safety distance should be entered in the Settings
dialog.
3
3 ³9DULDEOHLQFUHPHQW³7KLVSDUDPHWHUVKRXOGEHNHSWWR
zero when not being used.
C75
Section 4 Facing
Notes
You can return to the previous page with the following sequence:
After parametrising the setting data, you can parameterise the MDA
Facing cycle with the following data:
The values in the above dialog are for the following example:
C75
Section 4 Facing
Notes
Description of the parameters in the FACE TURNING working window.

Parameter Explanation

Tool Selected tool to be used in the working
cycle.

Feed F Selected path feedrate, in mm/min or
mm/rev.

Spindle S rpm selected spindle speed

Mach Definition of the surface quality.
You can select between roughing or
finishing.

Diameter DN input of the blank diameter of the part.

Z0 Blank dimension Input of the Z position.

Z1 Cutting dimension Cutting dimension, incremental.

DZ Cutting dimension Input of the cutting length in the Z
direction.
This dimension is always specified in
increments and is referred to the
workpiece edge.

UZ Max. infeed Stock allowance in the Z direction.

UX Max. infeed Stock allowance in the X direction.
The following sequence accepts the parameters for the MDA facing cycle,
and starts the machining sequence in MDA:
C75

C76 MDA Mode - Milling
1 Brief description
Module objective:

Upon completion of this module you can execute commands in the MDA mode.
Module description:

You can enter program commands in MDA and immediately execute them. This allows the operator
to activate functions on the machine normally for setting up purposes outside the NC program.

Module content:

Save MDA to program
Face milling


Section 2
Save MDA to program

Section 3
Face milling
Section 4
C76
Section 2 Functionality of MDA
Notes
The following functions are possible in MDA mode, executing immediately
program blocks in the Machine area. It is possible to execute M functions,
especially for tool changing or activating clamping devices outside of the
NC program.

You can activate MDA in the following sequence:
To scratch on the workpiece (Set zero offset, measure tools manually)
Jog and MDA can be used with each other.
In MDA you can then call the tool with spindle speed and direction. Be
careful not to program M02 as this will have the effect of resetting the
given spindle speed and direction.
After NC start you can return to Jog and position the axis accordingly.

Example shows text typed into the MDA area and sequence for moving
the axis:
T1
M6
X0 Y0 S2000 M3
C76
Section 3 Save MDA to program
Notes
The content of the MDA buffer can be saved as an NC program, this can
later be used again.
Pre-conditions:
MDA-mode is active
Program blocks exist in the buffer.
To save MDA to a program select the following sequence:
1
2
1 ,QWKHZLQGRZ³6DYHDV³\RXFDQLQSXWWKHQDPHRIWKH
program in which the blocks will be saved.
2 The destination can be determined with the Select key (Drive
N:), the CF-card (Drive D:) or the RCS-connection can be selected.
The data will be saved with the following sequence:
C76
Section 4 Face milling
Notes
7KH³)DFHPLOOLQJÍXQFWLRQLVXVHGIRUVXUIDFHSUHSDUDWLRQSULRUWRPDFKLQ
ing in Automatic.
The return plane and safety distance should be entered in the Settings
dialog.
3
3 ³9DULDEOHLQFUHPHQW³7KLVSDUDPHWHUVKRXOGEHNHSWWR
zero when not being used.
C76
Notes
You can return to the previous page with the following sequence:
The values in the above dialog are for the following example:
C76
Notes
Description of the parameters in the FACE TURNING working window.

Parameter Explanation

Tool Selected tool to be used in the working
cycle.

Work offset Work offset to be selected in the pro-
gram

Feed F Selected path feedrate, in mm/min or
mm/rev.

Spindle S rpm selected spindle speed

Direction Select the direction of rotation of the
spindle.

Mach Definition of the surface quality.
You can select between roughing or
finishing.

X0, Y0, Z0 select the geometry of the workpiece.
X1, Y1
Blank dimensions

Z1 Finish dimension Finishing dimension in the Z

DXY Max. infeed Input the amount of the infeed motion
(X, Y).

DZ Max. infeed Input the amount of the infeed motion
(Z)

UZ Input the stock allowance when
roughing.

The following sequence accepts the parameters for the MDA facing cycle,
and starts the machining sequence in MDA:
C76

C71 Turning tools and workplanes
1 Brief description
Module objective:

Upon completion of this module you can define new tools and also parameterise them.
Module description:

A description of the tools which are supported by the controller and also how they are parameterised
can be found in this module
Module content:
Tool geometry and workplanes

New turning tool
Tool setting on the machine
Drilling tools

Tool geometry and

workplanes
Section 2
New turning tool

Section 3
Tool setting on the ma-

Section 4
chine
Drilling tools
Section 5
Exercise
Section 6
Section 2 Tool geometry and workplanes
Notes
When working on a turning machine with turning tools, the workplane is
determined from the Z± axis (=1st. Axis in plane) and the X-axis (=2nd.
Axis in plane).
A simple turning machine has no Y axis. When working with driven tools,
the necessary Y axis functionality is achieved with an interpolation of the C
axis (Virtual Y axis functionality is achieved).

Therefore the following is the workplane which is active on a turning
machine.
To activate this in the part program G18 has to be programmed.

The Y axis (Blue arrow) is not available on simple turning machines.

It is important for the programming of a turning machine to observe first
whether the tool is in front of the turning centre or behind.
Turning in front of the turning Turning behind the turning
centre line centre line
Notes
When working with turning machines which are having their tools in front of
the turning centre the G18 coordinate system puts the Y axis in the
direction of the floor as opposed to the up direction when the turning tools
are behind the turning centre. This affects the direction of circles and also
the radius compensation of tools in the plane and care for this should be
taken.

The following graphic should help to explain this phenomenon:

X + behind turning centre
G03
G02
G02 G03
G03 G02 G03
G02
X + in front of turning centre
Notes
The tool length offset is applied to the axis dependent upon the plane
which is active, with G18:

Length 1: - Calculated in the X direction
Length 2: - Calculated in the Z direction
Radius: - Z/X-Plane
In parallel to the length and radius offsets, the orientation of the turning
tool has to be given into the control. This Orientation is necessary for the
cycles and radius compensation functions to correctly calculate the
contour intersections without collisions.

The following values are possible:
Section 3 New turning tool
Notes
The geometry of the tool has to be entered into the tool offset screen
before it can be used on the machine in a part program.

The following sequence shows how to perform this task.
1
2
1 Enter the tool number at this position.
2 Enter the tool type at this position.
After this procedure the tool appears in the tool list.
The length and radius of the tool can now be entered in the left geometry
fields.

Example:
Important:

After each value is entered this key must be pressed.
Section 4 Tool setting on the machine
Notes
It is possible to determine the length of the tool in X and Z simply, directly
on the machine.
A prerequisite for this, is a workpiece with known position and size
(diameter) located in the chuck.

To scratch on the surface of the workpiece, the spindle should first be
started in MDA.

The following sequence can be followed.
T1
G95 S500 M4
Do not program in MDA the M02 function as this will result in the spindle
stopping immediately.

To move the axis manually you first have to switch to JOG mode.

With the axis keys you can move the tool to the workpiece.
For an exact measurement when close to the component, the INC mode
should be used:
Notes
Using the VAR key repeatedly, can change the size of the INC to be used,
as seen in the following sequence:
Move the tool tip to a known diameter.
To set Length 1 follow the sequence:
1
1 Enter a diameter at this position.
To show that the data has been set, this text will be shown.
Notes
Move the tool tip to a known datum on the face.
2
2 Enter a length at this position if using a setting block.
Section 5 Drilling tools
Notes
A difference between turning and drilling tools exists in the control, drills
have only a length in the control.
The length can be determined with the same steps as in the last section.
For all simple drilling operations, G17 must be selected in the
NC program.
Move the tool tip onto a known datum on the face.
3
Section 6 Exercise
Notes
Create six tools.

1/ Rough turning tool. Tool number 1. External. Tip radius 0.8mm
2/ Finish turning tool. Tool number 2. External. Tip radius 0.4mm
3/ Grooving tool. Tool number 3. External. 3.1mm wide
4/ Threading tool. Tool number 4. External.
6/ Drilling tool. Tool number 6. 6.5mm diameter
7/ Tapping tool. Tool number7. 8mm diameter

Below shows what the tool offset page will look like.

C72 Milling tool and workplanes
1 Brief description
Module objective:

Upon completion of this module you can define new tools and also parameterise them.

Module description:

A description of the tools which are supported by the controller and also how they are parameterised
can be found in this module.
Module content:
Tool geometry and workplanes

New milling tool
Tool setting on the machine
Drilling tools

Tool geometry and

workplanes
Section 2
New milling tool

Section 3
Tool setting on the ma-

Section 4
chine
Drilling Tools
Section 5
Exercise
Section 6
Notes
2.1 Tool geometry and workplanes
Work plane for milling.
When working on a milling machine with milling tools, the work plane is
determined from the X-axis (=1st. axis in plane) and the Y-axis (=2nd. axis
in plane).

The Z axis is the infeed axis and is perpendicular to the plane X/Y plane.

Therefore the following is the workplane which is active on a milling
machine.
To activate this, in the part program G17 has to be programmed.

The G18 or G19 plane can be selected when a spindle attachment (rotary
head etc.) is used which places the orientation of the spindle into the X or
Y axis.

Notes
The tool length offset is applied to the axis dependent upon the plane
which is active, with G17:

Length 1: - Calculated in the Z direction
Radius: - XY-plane
Section 3 New milling tool
Notes
The geometry of the tool has to be entered into the tool offset screen
before it can be used on the machine in a part program.

1
1 Enter the tool number at this position.
After this procedure the tool appears in the tool list.
The length and radius of the tool can now be entered in the left geometry
fields, manually if need arises.

Example:
Important:

After each value is entred this key must be pressed.
Notes
It is possible to determine the length of the tool in Z simply and directly on
the machine.
A prerequisite for this, is a workpiece with known position and size
(diameter) located in the chuck.

To scratch the surface of the workpiece, the spindle should first be started
in MDA.

The following sequence can be followed.
T1
M6
G95 S2000 M3
Do not program in MDA the M2 instruction as this will result in the spindle
stopping immediately.

To move the axis manually you first have to switch to JOG mode.
With the axis keys you can bring the tool to the workpiece.
For an exact measurement close to the component, the INC mode should
be used:
Notes
Using the VAR key repeatedly, can change the size of the INC to be used,
as seen in the following sequence:
Move the tool tip to a known diameter.
1
2
1 Enter a length of the setting block at this position if using a
setting block.
2 Enter the height from the reference plane at this position.
Notes
You can also measure the diameter of the cutter using the following
sequence.
1
2
3
setting block.
2 Enter the length from the reference plane in the X axis at this
position.
3 Enter the length from the reference plane in the Y axis at this
position.
Section 5 Drilling tools
Notes
The only between a milling cutter and a drill is a drill has no diameter to
set, drills have only a length in the control.
The length can be determined with the same steps as in the last section.
Move the tool tip onto a known datum on the face.
To set Length 1 follow this sequence.
3
4
setting block.
4 Enter the height from the reference plane at this position.
Section 6 Exercise
Notes
Create six tools.

1/ 60mm Diameter cutter
4/ 12mm centre drill
5/ 8.2mm drill
6/ M10 Tap

Below shows what the tool offset page will look like.

Notes

C73 Work offsets - turning
1 Brief description
Module objective:

Upon completion of this module you will be able to set the zero offset on a turning machine

Module description:

This module shows how to set the zero offset on a turning machine, and helps you to understand it´s
purpose.
Module content:
Overview of the coordinate system

Zero offset page in the control
Setting the zero offset

Overview of the coordi-

nate system
Section 2
Zero offset page in the

control Section 3

Section 4
Section 2 Overview of the coordinate system
Notes
Description of the zero offset:

The zero offset determines the difference between the Machine
Coordinate System (MCS) and the Workpiece Coordinate System (WCS).

For programming, the dimensions are with reference to the Workpiece
Coordinate System.
The exact position of the workpiece on the machine is not known at the
time of writing the workpiece program.
The distance between the machine zero point and the workpiece zero
point must therefore be obtained.
This geometric difference is known as the zero offset.
The following diagram gives an overview of the offset possibilities of the
control:
TRANS
Programmable Zero Offset

G500.G53

TRANS X Z, ATRANS X Z

Work coordinate System WCS

G54
G153

$P_UIFR[1,X Z,TR]
Base Coordinate System BCS

G500
$P_UIFR[0,X Z,TR] Machine Coordinate System MCS

Description of the single components:
Machine Coordinate System (MCS):

The machine coordinate system is determined by the manufacturer of the
machine, the value (0) is determined at the 1st setup by the builder and
should only be changed by experienced service personnel.
The G code G153 can be used blockwise to perform a move in the MCS at
any time in the program.
NOTE: The instruction G153 is only blockwise active!

Notes
Base Coordinate System (BCS):
The Base Coordinate System works between the Machine Coordinate
System and the Workpiece Coodinate System. If the value of the Base
Coordinate System is changed, then the Workpiece Coordinate System
will move respectively.
The Base Coordinate System is activated with G500. When G500 is
programmed the modally active (G54) will be deactivated.
With G54 active a movement can be programmed with respect to the BCS
by using the blockwise G code G53.

Workpiece Coordinate System (WCS):
The workpiece coordinate system is the offset between the BCS and the
origin of the component.
When the BCS system has no value, then the WCS is the offset to the
MCS system.

7 Zero offsets are therefore available to the operator/programmer.

G500 - Basic Zero Offset
G54 - 1st. Zero Offset
G55 - 2nd. Zero Offset
G56 - 3rd. Zero Offset
G57 - 4th. Zero Offset
Section 3 Zero offset page in the control
Notes
An offset page is available in the control, where the operator of the ma-
chine can input and check the zero offset values.

When working with a turning machine an offset in X is normally not
nessesary.
A BCS offset can be used to offset the front of the chuck from the MCS. A
WCS offset can then be used for the origin of the workpiece.

All values can be edited on the offset page.

To simplify the input a pocket calculator is integrated into the control:

By pressing the equals key in the respective

input field, the calculator will start.
Notes
After pressing the equals key the value from the input field will
automatically be inserted into the calculator for further processing.
The calculation takes place with the following sequence.
And the calculation is trasfered to the zero offset page with the following
sequence.
1
1 The calculated value will be transferred into the input field.
With the parameter field
A coordinate rotation can also be calculated.
Section 4 Setting the zero offset
Notes
The zero offset on a turning machine is normally only used in the Z axis,
the X axis stays at 0 (spindle centre line).
Therefore: from left to right in the diagram below the BCS offsets the MCS
and the WCS offsets the BCS.
WCS
MCS
WCS
WCS
MCS BCS
The scratch method is used to set the zero offset, the spindle should
therefore be started in MDA.
T1 D1
S200 M4
Touch the workpiece using the axis direction

buttons.
Notes
The following sequence shows how to set the zero offset automaticlly on
the machine.
1
2
1 You can select the required offset with the Toggle field using
the SELECT softkey, into which zero offset the value should be
stored.
The value will be calculated and stored with the following sequence.

Notes

C74 Work offsets - Milling
1 Brief description
Module objective:

Upon completion of this module you will be able to set the zero offset on a milling machine.
Module description:

This module shows how to set the zero offset on a milling machine, and helps you to understand its
purpose.
Module content:
Overview of the coordinate system

Zero offset page in the control

Overview of the coordi-

nate system
Section 2
Zero offset page in the

control Section 3

Section 4
C74
Notes
Description of the zero offset:

The zero offset determines the difference between the Machine
Coordinate System (MCS) and the Workpiece Coordinate System (WCS).

For programming, the dimensions are with reference to the Workpiece
Coordinate System.
The exact position of the workpiece on the machine is not known at the
time of writing the workpiece program.
The distance between the machine zero point and the workpiece zero
point must therefore be obtained.
This geometric difference is known as the zero offset.
The following diagram gives an overview of the offset possibilities of the
control:
TRANS
Programmable Zero Offset

G500.G53

TRANS X Z, ATRANS X Z

Work coordinate System WCS

G54
G153

$P_UIFR[1,X Z,TR] Base Coordinate System BCS

G500
$P_UIFR[0,X Z,TR] Machine Coordinate System MCS

Description of the single components:
Machine Coordinate System (MCS):

The machine coordinate system is determined by the manufacturerer of
the machine, the zero value is determined at the 1st setup by the machine
tool builder and should only be changed by experienced service personnel.
The G code G153 can be used blockwise to perform a move in the MCS at
any time in the program.
NOTE: The instruction G153 is only blockwise active!
C74
Notes
Basic Coordinate System (BCS):

The Basic Coordinate System works between the Machine Coordinate
System and the Workpiece Coodinate System. If the value of the Basic
Coordinate System is changed, then the Workpiece Coordinate System
will move respectively.
The Basic Coordinate System is activated with G500. When G500 is
programmed the modally active (G54) will be deactivated.
With G54 active a movement can be programmed with respect to the BCS
by using the blockwise G code G53.

Wokpiece Coordinate System (WCS):
The workpiece coordinate system is the offset between the BCS and the
origin of the component.
When the BCS system has no value, then the WCS is the offset to the
MCS system.

7 Zero offsets are therefore available to the operator/programmer.

G500 - Basic Zero Offset
G54 - 1st. Zero Offset
G55 - 2nd. Zero Offset
G56 - 3rd. Zero Offset

C74
Notes
An offset page is available in the control, where the operator of the
machine can input and check the zero offset values.

When working with a milling machine a BCS offset can be used to offset the
surface of the clamping device from the MCS. A WCS offset can then be
used to the origin of the workpiece.

All values can be edited on the offset page.

To simplify the input a pocket calculator is integrated into the control:
By pressing the equals key in the respective

input field, the calculator will start.
C74
Notes
After pressing the equal key the value from the input field will automatically
be inserted into the calculator for further processing.
The calculation takes place with the following sequence.
And the calculation is trasfered to the zero offset page with the following
sequence.
1
1 The calculated value will be transferred into the input field.
With the parameter field
A coordinate rotation can also be calculated.
C74
Notes
On a milling machine a value in all three geometry axis has to be set.

The offset is set using the scratch function in the control, to use scratch the
spindle should first be started in MDA.
T1 ;; manual 3D-Dial indicator

M6
Drive to the surface of the

workpiece until indication.
C74
Notes
The following sequence shows how set the zero offset automaticlly on the
machine.
1
2
3
1 You can select the required offset with the Toggle field using
the SELECT softkey, into which zero offset the value should be
stored.
2 You can select the required directionwith the Toggle field.
The value will be calculated and stored with the following sequence.
C74
Notes
This should then be repeated for the X and Y axes respectively.
C74

C81 Automatic mode - Turning
1 Brief description
Module objective:

Upon completion of this module you can select and run an NC part program
Module description:

This module describes the steps which have to be taken to select and run an NC part program.
Module content:
Select part program

Starting a program
Block Search

Select part program

Section 2
Starting a program
Section 3
Block search
Section 4
C81
Section 2 Select part program
Notes
Before an NC program can be started in automatic, it must first be se-
lected.

7KHSURJUDPLVVHOHFWHGLQWKH³3URJUDP0DQDJHU´XVLQJWKHIROORZLQJ
sequence.
Auto
First the relevant directory has to be opened.

The required directory can be highlighted with the cursor keys.
The directory can be opened with the following keys.
or
C81
Notes
The program now has to be selected, use the following sequence.
The required program can be highlighted with the cursor keys.
1 This softkey will transfer the required NC

program into Automatic area and will be shown
on the screen at this position.
1
C81
Section 3 Starting a Program
Notes
Requirements prior to NC-Start.

The Automatic mode has to be selected prior to NC-Start.
The machine builder may also state prerequisites, read the handbook of
the machine tool builder

It is possible with Single Block, to process one block at a time. To execute
the whole part program this requires subsequent presses of the NC Start
key.

The SINGLE BLOCK key can be found on the machine control panel:
Whether or not SINGLE BLOCK is active can be seen on the Status line of
the control, as in the following diagram:
The SINGLE BLOCK function can be deactivated by pressing the key a
second time.
The machine Stops at the end of the current block when the SINGLE
BLOCK key is pressed in program.
The feedrate override can be used additionally to control the velocity af the
axis.
NC-Start
Taking care of the above mentioned functions you can continue with the
Cycle Start key.
C81
Section 4 Block Search
Notes
A block search is performed, so that an operator can begin at a suitable
point other than the start of the NC program. This is achieved by following
the sequence.
1
1 This softkey will allow you to choose which part

of the program to start from.
This button can be used to cursor down to the
required position in the program.
C81
Notes
Or this soft key can be used to find a specific point
in the program e.g. block number or tool number.
)ROORZHGE\³WRFRQWRXU´WKHQ³F\FOHVWDUW´
You have to press the cycle start button a second

time to acknowledge the above alarm so that the
program will execute in Auto mode.
C81

C81 Automatic Mode - Milling
1 Brief description
Module objective:

Upon completion of this module you can select and run an NC part program
Module description:

This module describes the steps which have to be taken to select and run an NC part program.
Module content:
Select part program

Starting a program
Block Search

Select part program

Section 2
Starting a program
Section 3
Block search
Section 4
C81
Notes
Before an NC program can be started in automatic, it must first be se-
lected.

7KHSURJUDPLVVHOHFWHGLQWKH³3URJUDP0DQDJHU´XVLQJWKHIROORZLQJ
sequence.
Auto
First the relevant directory has to be opened.

The required directory can be highlighted with the cursor keys.
The directory can be opened with the following keys.
or
C81
Notes
The program now has to be selected, use the following sequence.
The required program can be highlighted with the cursor keys.
1 This softkey will transfer the required NC

program into Automatic area and will be shown
on the screen at this position.
1
C81
Section 3 Starting a Program
Notes
Requirements prior to NC-Start.

The Automatic mode has to be selected prior to NC-Start.
The machine builder may also state prerequisites, read the handbook of
the machine tool builder

It is possible with Single Block, to process one block at a time. To execute
the whole part program this requires subsequent presses of the NC Start
key.

The SINGLE BLOCK key can be found on the machine control panel:
Whether or not SINGLE BLOCK is active can be seen on the Status line of
the control, as in the following diagram:
The SINGLE BLOCK function can be deactivated by pressing the key a
second time.
The machine Stops at the end of the current block when the SINGLE
BLOCK key is pressed in program.
The feedrate override can be used additionally to control the velocity af the
axis.
NC-Start
Taking care of the above mentioned functions you can continue with the
Cycle Start key.
C81
Notes
A block search is performed, so that an operator can begin at a suitable
point other than the start of the NC program. This is achieved by following
the sequence.
1
1 This softkey will allow you to choose which part

of the program to start from.
This button can be used to cursor down to the
required position in the program.
C81
Notes
Or this soft key can be used to find a specific point
in the program e.g. block number or tool number.
)ROORZHGE\³WRFRQWRXU´WKHQ³F\FOHVWDUW´
You have to press the cycle start button a second

time to acknowledge the above alarm so that the
program will execute in Auto mode.
C81

C1 RCS802 Data Transfer Tool

Version 1.4
Section 1 Brief description
Module objective:
Upon completion of this module you can:-
Connect to the controller and transfer data using The RCS802 Data Transfer Tool.
Understand the use of licences
Use Sinumerik 802D Snapshot.
Module description:
Data resident on the controller can be saved to an external Laptop/PC for backup purposes. This
data can be transferred back to the controller as and when required.
Alternatively, data created off-line such as part programs can be transferred to the controller in the
same way.
This module describes the three methods of connecting to the controller and shows an example of
how the RCS802 Data Transfer Tool can be used to save/restore data.
Module content:
Description of
RCS802
Section 2
RS232C-
Online Section 3
connection
Ethernet-
Peer to Peer online Section 4
connection
Ethernet-
Network online Section 5
connection
Data transfer with

802D sl Section 6
Sinumerik 802D
Snapshot Section 7
SINUMERIK 802D sl Operating and Service Training Manual Page 1 Total pages=17 C1
C1

Section 2 Description of RCS802.
Notes
The RCS802 program is available as part of the toolbox supplied with the
controller.
The software can be used in several ways:-commissioning/service work,
data transfer and remote diagnosis.
Connection is via Ethernet or RS232.
There are two Ethernet connection methods:-Peer to Peer & Network.
The following pages will describe how to make a connection with each of
the above protocols.
Section 3 RS232C online connection

The following sequence of operations should be carried out to obtain an
online serial connection to the controller.
The PG/PC should be connected to the 802D sl controller (Socket X8) with
a standard RS232 cable.

The communication port on the controller must be activated.
Access the System area with the following simultaneous key presses:-
+
1RZVHOHFWWKH³3/&´VRIWNH\
This opens the page where the communication parameters are set up.
When the parameters have been set, the connection is activated with the
³&RQQHFW21´VRIWNH\


Notes
:KHQWKHFRQQHFWLRQLVDFWLYDWHGWKH³&RQQHFW21´VRIWNH\FKDQJHVWR
³&RQQHFW2))´

Also a connection icon appears at the bottom right of the screen.
The RCS802 program should now be opened.
&KRRVHWKH³56>9@´RSWLRQIURPWKH³&RQQHFWYLD´GURSGRZQPHQX
7KHQVHOHFWWKH³FRQQHFWÉXWWRQ
Now the relevant communication port of

the PG/PC can be selected and then
configured.

The settings should be changed to match the controller settings set on Notes
page 2.
1RZVHOHFWWKH³2.ÉXWWRQ7ZLFH
The connection should now be complete. This is confirmed by the
appearance of the 802D sl drives in the bottom of the left hand window
Another indication of a successful connection is the appearance of the
following icon in the bottom right hand of the controller screen.

Section 4 Ethernet-Peer to Peer online connection
To use the Peer to Peer method of connection first connect the PG/PC to Notes
socket X5 on the controller using a crossover Ethernet cable.
The connection on the controller is activated first. This is done from the
³6\VWHP´DUHD

+
The following sequence of softkey presses is then followed.

The following page is then shown as the port is activated.
The IP Address and subnet mask are default and are independent of the
VHWWLQJVLQLQWKH³6HUYLFHQHWZRUN´DUHDZKLFKDUHGLVDEOHGZKHQWKH
³3HHUWR3HHU´PRGHLVVHOHFWHG

Section 4 Ethernet-Peer to Peer online connection
7KH5&6VRIWZDUHLVQRZRSHQHGDQGWKH³(WKHUQHW>SHHUWRSHHU@´ Notes
option selected from the drop down menu.
7KH³&RQQHFWÉXWWRQLVWKHQVHOHFWHG
The dialogue box is for information only and shows the default IP settings
of the controller. No changes can be made.
7KHSURFHGXUHLVFRPSOHWHGZLWKWKH³2.ÉXWWRQ
If the connection is successful, the drives of the

controller can be seen in the left hand window of
the RCS802 Software, also the following icon
appears in the bottom right of the controller
screen.

Section 5 Ethernet-Network online connection
Licences Notes
7KLVPHWKRGRIFRQQHFWLRQLVSULPDULO\IRU³5HPRWH'LDJQRVWLFV´XVH
To function correctly a licence is required.
7RFKHFNZKHWKHUDOLFHQFHLV,QVWDOOHGWKH³$XWRPDWLF/LFHQFH0DQDJHU´
software is opened from the Start Menu.
The example above shows that the RCS802 Licence is stored on the C Drive
along with the licences of other software applications.
The licences can be transferred to/from other media such as floppy drives,
PHPRU\VWLFNVHWFYLDWKH³/LFHQFH.H\´0HQX
Making a connection
7RVHWWKHFRQWUROOHUXSWRFRPPXQLFDWHHQWHUWKH³6\VWHP´$UHD-
+
The password needs to be active to a minimum of level 3 (Customer).
Module C21 explains the various protection levels

A user must also be logged in. There are three default users, SIEMENS,
SERVICE and PEERTOPEER.
The SIEMENS user is not available for general use.
The PEERTOPEER user is automatically logged in when the
³(WKHUQHW-3HHUWR3HHU´FRQQHFWLRQGHVFULEHGLQVHFWLRQLVVHOHFWHG
The SERVICE user is available for use and will be used for this module.
The password for this user is:-$SERVICE$.
7RORJLQWRDQH[LVWLQJDFFRXQWWKH³5&6ORJ-LQ´VRIWNH\LVXVHG

7KHXVHUQDPHDQGSDVVZRUGDUHHQWHUHGIROORZHGE\WKH³/RJLQ´ Notes
Softkey.
8VHWKH³%DFN´VRIWNH\WRUHWXUQWRWKH³6\VWHP´SDJH
If a new user is to be added, follow the following softkey sequence:-
$XVHUQDPHDQGSDVVZRUGFDQQRZEHHQWHUHGIROORZHGE\WKH³2.´
softkey.

Notes
The newly created user now appears in the list.
7RFRQWLQXHVHWWLQJXSWKHFRQWROVHOHFWWKH³%DFN´VRIWNH\
This page is used for entering network settings. These settings will depend
on the type of remote access required. For a simple connection between
the controller and a PC/PG we are interested in the IP address and Subnet
mask. More detailed information will be required for connection via factory
networks etc.

$Q\FKDQJHVWRWKHQHWZRUNVHWWLQJVDUHDFWLYDWHGZLWKWKH³6DYH´WKHQ Notes
³2.´VRIWNH\V
Now that the controller is setup the RCS802 program is opened. From the
GURSGRZQPHQXWKHRSWLRQ³(WKHUQHW>QHWZRUN@´LVVHOHFWHG
:KHQWKH³&RQQHFWÉXWWRQLVVHOHFWHGDGLDORJXHER[ZLOODSSHDU7KHQWKH
³&RQILJXUHÉXWWRQPXVWEHVHOHFWHG

Notes
This is where the connection can be named and the IP address of the
controller we are connecting to entered.
6HOHFWWKH³$GGÉXWWRQDQGHQWHUWKH6WDWLRQQDPHDQG,3DGGUHVVIROORZHG
E\WKH³6DYHÉXWWRQDQGWKH³2.ÉXWWRQ

Notes
In the dialogue box, enter the log on name and password of the user which is
FXUUHQWO\ORJJHGLQRQWKHFRQWUROOHU7KHQVHOHFW³2.´
A successful connection is shown by the 802D sl drives appearing in the left
hand window of the RCS802 program.
Another indication of a successful connection is the appearance of the
following icon in the bottom right hand of the controller screen.

Section 6 Data Transfer with RCS802
Saving data to external PG/PC Notes

Data such as programs can be transferred to and from the controller using
the RCS802 software.
The directory structure and functionality of the software is similar to
Windows Explorer.
Example:-To create an NC/PLC/DRIVES series start up file, right click on
WKHIROGHUQDPHG³6WDUW-XSDUFKLYH1&3/&'ULYH´DQGVHOHFWWKHFRS\
option. Now select a destination on the PC/PG, right click and paste the
file.
If you need to change the name of the archive from default you can do this
KHUHE\VHOHFWLQJ³<HV´(QWHUWKHGHVLUHGILOHQDPHIROORZHGE\³6DYH´

The progress of the data transfer is displayed Notes
Once the transfer is complete a logfile of the transferred files can be viewed.
Restoring Data with external PG/PC

The control can be restored using the same method. The Archive file is
FRSLHGIURPWKH3*3&WRWKH³6WDUW-XSDUFKLYH1&3/&'ULYHÍROGHURI
Drive A on the controller.

Notes
Allow data transfer to complete then view the logfile if required
$IWHUWKH³2.ÉXWWRQLVVHOHFWHGWKHFRQWUROOHUZLOOUHERRW
Certain dialogue boxes will be shown on the controller which are quite
normal. The procedure finishes with an NCK reset and resets the password
as well as the RCS802 losing connection with the controller.


In this example an NCK archive was created and restored. Individual data Notes
such as Tool Offsets, Part Programs etc can be copied and pasted to and
from the controller. The screen below shows the contents of the MPF
directory. This is reached by expanding the menu tree in the left hand
Window. Other data is found in the same way.
As well as the three drives on the controller (Drives A, N & F), data can be
transferred to and from the other drives (Drives D & G) Provided that the
media has been inserted i.e. CF card in drive D and USB memory device
in drive G
Section 7 Sinumerik 802D Snapshot
7KH5&6VRIWZDUHSDFNDJHDOVRKDVDIXQFWLRQFDOOHG³6QDSVKRW´
/LNHWKH³(WKHUQHW>1HWZRUN@´RSWLRQWKLVLVGHSHQGDQWRQDOLFHQVH6HH
page 7)
,IDOLFHQFHLVGHWHFWHGWKH³6LQXPHULN'6QDSVKRWÉXWWRQLVDYDLODEOHRQ
the toolbar. No licence and the button will be greyed out.
Selecting this button will open up a window which will show exactly the same
screen that the controller is showing.
When the mouse pointer is on the Snapshot screen and right click is selected,
a list is displayed which can be used to replicate key board functions.
Changing a screen via Snapshot will result in the screen changing on the
controller.

This is very useful for Remote Diagnosis and service/commissioning work.

Section 7 Sinumerik 802D Snapshot
&OLFNWKH³6LQXPHULN'6QDSVKRWÉXWWRQWRVKRZDUHDO-time display of the Notes

controller screen
Right click the mouse over the Snapshot screen to get a list of keyboard
functions.
End of Module C1


Blank Page Notes

C104 Mould & Die Functionality and Programming

- Milling
1 Brief description
Module objective:

Upon completion of this module you can transfer, edit / program and execute a Mould & Die program
on the 802Dsl.

Module description:

Mold & Die functions and commands allow to execute especially large programs with G1 blocks.

Module content:
Mould & Die short description

Mould & Die commands
Transfer, edit and execute program
Program Example
Mould & Die

short description
Section 2
Mould & Die

commands Section 3
Transfer, edit and exe-

Section 4
cute a program
Program Example
Section 5
C104
Section 2 Mould & Die short description
Notes
Introduction

CAD -> CAM -> CNC process chain

Many CNC programs for freeform surface machining come from
CAM systems. The CAM system obtains the workpiece geometry
from a CAD system.

When executing CAM programs in the HSC range for Mold&Die, the
control has to process high feedrates with short NC/G1 blocks with
síngle points. The user expects good surface finish with great
accuracy in the µm range with high machining feedrates up to
10 m/min. By applying different machining strategies, the user can
ÄILQHWXQH³WKHSURJUDPZLWKWKHDLGRI6LQXPHULNDSSOLFDWLRQ
commands.
When roughing, speed is the priority due to smoothing the contour.
When finishing, accuracy and surface quality is the priority.
In both cases, specifying a tolerance ensures that the machining
contour is observed in order to achieve the desired surface finish.
When defining the tolerance value for smoothing the contour, the
operator must have knowledge of the subsequent CAM program.
C104
Section 3 Mould & Die commands
Notes
List of G Codes
The following G Codes are relevant for Mold & Die

G Code Group4 : FIFO
STARTFIFO / STOPFIFO / FIFOCTRL

Recommended function : FIFOCTRL

Preprocessing memory control - Avoids that the FIFO buffer runs empty

G Code Group10 : EXACT STOP - CONTINUOUS PATH MODE
LOOK AHEAD
G60 / G64 / G641 / G642

Recommended function : G642

Use of LOOK AHEAD:
The purpose of continuous-path control is to increase speed and harmonize
traversing performance. In path control function this is achieved with two
functions.
Look ahead - Look ahead speed control :
The control system calculates several NC blocks ahead and determines a
modal speed profile. The way in which this speed control is calculated can be
set with functions G64 or G642.

Recommended function : Corner rounding G642
The look ahead function also means that the control system is able to round
the corners it detects. The programmed corner points are therefore not
approached exactly. Sharp corners are rounded.
Insertion of Circle or Spline elements.

1
1 Corner Rounding G642
C104
Notes

G Code Group21 : ACCELERATION PROFILE
BRISK / SOFT / DRIVE

Recommended function : SOFT

Soft smoothed path acceleration

To make acceleration as gentle on the machine as possible, the
acceleration profile of the axes can be influenced by means of the
commands Soft and Brisk. If Soft is activated, the acceleration
behavior does not change abruptly but is increased by a linear
characteristic. This reduces the load on the machine. It also has a
beneficial effect on the surface quality of workpieces, since machine
resonance is excited far less frequently.
The axis slides travel with constant acceleration until the feedrate is
reached. SOFT acceleration enables higher path accuracy and less
wear and tear on the machine.

C104
Notes

G Code Group24 : FEEDFORWARD CONTROL
FFWOF / FFWON

Recommended function : FFWON

Feed forward control ON

Feedforward control function FFWON
Following errors cause contour violation. 1 The inertia in the system
means that the cutter tends to leave the setpoint contour - 2 -
tangentially, i.e.the actual contour - 3 - that is produced deviates from
the setpoint contour. Following errors are due to a combination of the
system -- positioning control - and the speed.
Feedforward control FFWON reduces speed - dependent following
errors when contouring almost to zero. Traversing with feedforward
control permits higher path accuracy and thus improved machining
results.

C104
Notes

G Code Group30 ² COMPRESSOR ON/OFF
COMPOF / COMPON / COMPCURV / COMPCAD

This function is only available for SINUMERIK 802D sl pro.

Recommended function : COMPCAD

CAD/CAM systems usually deliver linear blocks which observe the
parameterized accuracy. With complex contours, this results in a
substantial data quantity and ± in some cases short path sections.
These short path sections limit the machining speed. By using the
compressor, it is possible to summarize short path blocks in a path
section. The number of blocks to be executed is compressed.
By using the COMPCAD Gcode, you can select a compression
optimized with reference to the surface quality and the velocity,
whereby the accuracy of the interpolation can be defined via
machine data $MA_COMPRESS_POS_TOL - MD33100 .
According to the specified tolerance band - 1 - the compressor
combines a sequence of G1 commands - 2 - and compresses them
into a spline - 3 - which is directly calculated by the control system.
This makes the surface much smoother, since the machine axes can
move more harmoniously and machine resonance is avoided.This
allows higher traversing speeds and reduces the load on the
machine.
This compression operation can only be executed on linear blocks
(G1). It is interrupted by any other type of NC instruction, e.g., an
auxiliary function output, but not by parameter calculations. Only
those blocks containing nothing more than the block number, G1,
axis addresses, feed and comments are compressed. All other
blocks are executed unchanged (no compression).

C104
Notes
Programming Commands
Programming functions :
Tolerance of the axes used for machining.

$MA_COMPRESS_POS_TOL[ AXIS]= Tolerance Value

AXIS MD 33100 2

The tolerance value applies with G642 and COMPCAD. The
tolerance value is written to the relevant machine data.
This tolerance value should be the same or a a little bit higher 10-
20%, than the chord tolerance band of the CAM system.

Freeform Surface:

P2
P1
Chordal Error
P3
Ideal Cutter Path

Linearized Cutter Path

Tolerance Band
To change this machine data the Manufacturing password

2
has to be set
C104
Section 4 Transfer, edit and execute program
Notes
Transfer and copy a program

With 802Dsl pro it is possible to copy a program <= 3MB directly
into the controller - program manager.
Follow the sequence below.
Highlight the files you wish to transfer to the NC
C104
Notes
Note: The NC Memory for the operator on the 802Dsl pro is max 3MB.
Programs larger than 3MB could only be stored and executed from
the CF Card.
C104
Notes
Edit a program

With 802Dsl pro it is possible to edit every program <= 3MB directly
on the controller in the menu program manager. Programs > 3MB
could only be edited and changed on an extern medium i.e. PC.
Use the following sequence to open and edit programs in the NC directory.
Highlight the file using the following buttons.
The directory and, or file can be opened with the following keys.
or
C104
Notes
C104
Notes
Execute a program

With 802Dsl pro it is possible to execute a program in two ways .
Execute from the controller NC Memory and execute from CF Card
Use the following sequence to open and execute programs in the NC
directory.
The directory and, or file can be executed with the following key.
When in the NC DIRECTORY the program is executed directly from the
NC Memory.
C104
Notes
The directory and, or file can be executed with the following key.
When in the CUSTOMER CF CARD the program is executed from the CF
Memory card.
C104
Section 5 Program Example
Notes
Program Roughing
Short Description:
Tool : End Mill 6mm
CAM Chordal Tolerance : 0.05 mm
Program Size : 186 KB - 7778 lines

Program Header:
C104
Section 5 Program Example
Notes
Program Finishing
Short Description:
Tool : Ball Nose 3mm
CAM Chordal Tolerance : 0.005 mm
Program Size : 1,35 MB - 50338 lines

Program Header:

C104

Notes
C104

C95 ISO Dialect programming - Milling
1 Brief description
Module objective:

Upon completion of this module you will see that it is possible with 802D sl, ISO Dialect programming
for milling.

Module description:

ISO Dialect allows a non-Siemens NC program to be run within the control. This module describes
the functionality offered by standard functions. Differences and additions implemented by the
machine tool manufacturer are documented by the machine-tool manufacturer.

Module content:
Introduction to ISO dialect
Switch Over
ISO Dialect milling addresses
Milling G codes
Advanced level commands
Basic ISO Dialect program
Introduction to ISO dia-

lect
Section 2
Switch Over
Section 3
ISO Dialect milling ad-

Section 4
dresses
Milling G codes
Section 5
Advanced level com- Section 6

mands
Basic ISO Dialect pro-

Section 7
gram
C95
Section 2 Introduction to ISO Dialect
Notes
Siemens Mode

The following conditions apply when Siemens mode is active:

Siemens G functions are interpreted on the control by default.

It is not possible to extend the Siemens programming system
with ISO Dialect functions because some of the G functions
have different meanings.

ISO Dialect mode

The following conditions apply when ISO Dialect mode is active:

Only ISO dialect G codes can be programmed, not Siemens G
functions.

It is not possible to use a mixture of ISO Dialect code and Sie-
mens code in the same NC block.

If further Siemens functions are to be used, it will be necessary
to switch to Siemens mode first.
C95
Section 3 Switch Over to ISO Dialect
Notes
The following two G functions are used to switch between Siemens Mode
and ISO dialect Mode:

G290 - Siemens NC programming language active

G291 - ISO Dialect NC programming language active
1
2
1 In ISO dialect, you will see G291 in top left hand corner
2 In ISO dialect, you will see G291 H value in the T,F,S window.
C95
Notes
When writing the NC program the two G functions are placed at the top
and bottom of the program
G291 ;;ISO dialect Mode

G00 G90 G94 G40
G21 G17
T1
M6
...
...
...
...
G00 G40 Z2.0
X0.0 Y8.0 Z8.0
G290 ;;Siemens mode
M30
1
1 In ISO dialect, you will see G291 in top left hand corner
1RWHLI\RXSUHVV³5(6(7ÉXWWRQ

halfway through running an NC program, the control will revert back to Sie-
mens mode, as G290 is the default code.
C95
Section 4 ISO Dialect milling addresses
Notes
These are the different addresses that are used in ISO dialect.
Address Meaning
F Feed G94 (mm/inch per min)
F Feed G95 (mm/inch per rev)
F Thread pitch
C Chamfer
R Radius
Q
I, J, K Interpolation parameters
X G4 Time unit
A Contour Angle

C95
Section 5 Milling G codes
Notes
Here is a list of ISO dialect G codes that are fundamentally different to G
functions in Siemens mode.

Function
This function allows you to program an arc either clockwise (G02) or
counter-clockwise (G03) direction.

Programming
G02/G03 G90 X.. Y.. Z.. I.. J.. K.. F.. Absolute end point
Or
G02/G03 G91 X.. Y.. Z.. I.. J.. K.. F.. Incremental end point
Or
G02/G03 X.. Y.. Z.. R.. F.. Radius of arc

Dwell time G4

Function
hole
In the feed per minute mode (G94) the dwell time unit is in seconds,
while in the feed per revolution (G95) the dwell time unit is in spindle
revolutions.

Programming
G4 G94 X.. X = Time
Or
G4 G95 X.. X = Rotations

C95
Section 5 Milling G codes
Notes
Tool length offset (G43, G44, G49)

Function
The tool length offset function adds or subtracts the amount stored in
the tool offset data memory to or from the Z coordinate values speci-
fied in the program to offset the programmed paths according to the
length of a cutting tool.

Commands
In the execution of the tool length offset function, addition or subtrac-
tion of the offset data is determined by the specified G code and the
direction of offset by the H code.

Programming
**=«+« ;;tool offset is added to Z axis position
Or
**=«+« ;;tool offset is subtracted from Z axis position
Or
G49 ;;cancels the tool offset mode

Return value (G98, G99)

Function
When using canned cycles, the retraction level for the Z axis is deter-
mined through G98/G99. G98/G99 are modal G codes. G98 is usu-
ally set as power-on default.

Programming
**=«5«)
Or
**=«5«)
C95
Section 6 Advanced level commands
Notes
Canned cycles (G73 to G89)

Function
By using canned cycles, it is easier for the programmer to create
programs. By means of canned cycles, machining operations fre-
quently used can be determined in a single block through a G func-
tion. Normally more than one block is required when programming
without canned cycles. Using canned cycles can also shorten the
program in order to save memory.

G Code Description
G73 Deep hole drilling with chip break
G74 Counterclockwise tapping cycle
G76 Fine drilling cycle
G80 Cycle off
G81 Counterbore drilling cycle
G82 Countersink drilling cycle
G83 Deep hole drilling cycle with swarf removal
G84 Clockwise tapping cycle
G85 Drilling cycle
G86 Drilling cycle, retract using G00
G87 Back boring cycle
G89 Drilling cycle, retract using G01
C95
Section 6 Advanced level commands
Notes
Subprogram call up function (M98, M99)

Function
This function can be used when subprograms are stored in the part
program memory, subprograms registered to the memory with pro-
gram numbers assigned can be called up and executed as many
times as required
The created subprograms should be stored in the part program
memory before they are called up.

Commands
M98 ;;subprogram call up
Pxxxx ;;program number
Lyyyy ;;number of program runs
M99 ;;end of subprogram

Programming
M98 Pyyyyxxxx ;;
Or
M98 Pxxxx Lyyyy ;;

G291 200.mpf
: :
M98 P200 :
G00 G40 Z2.0 :
: :
: :
: M99
M30
Chamfering and corner rounding commands (R, C)

Function
It is possible to insert chamfering and corner rounding blocks auto-
matically between:
linear interpolation and linear interpolation
linear interpolation and circular interpolation
circular interpolation and linear interpolation
circular interpolation and Circular interpolation

Programming
&« ;;chamfering
5« ;;corner rounding

C95
Section 7 Basic ISO Dialect program
Notes
An ISO Dialect program using the same basic structure as a Siemens pro-
gram, but using instead an ISO Dialect drilling cycle (G81).
The above program running in auto mode

note the ISO in red text, below.
C95

C96 ISO Dialect programming - Turning
1 Brief description
Module objective:

Upon completion of this module you will see that it is possible with 802D sl, ISO Dialect programming
for turning - *A, B, C G code system).

Module description:

ISO Dialect allows a non - Siemens NC program to be run within the control. This module describes
the functionality offered by standard functions. Differences and additions implemented by the
machine tool manufacturer are documented by the machine-tool manufacturer.

Module Content:
Introduction to ISO dialect
Switch Over
ISO Dialect turning addresses
Turning G codes
Advanced level commands
Basic ISO Dialect program
Introduction to ISO dia-

lect
Section 2
Switch Over
Section 3
ISO Dialect turning

Section 4
addresses
Turning G codes
Section 5
Advanced level com- Section 6

mands
Basic ISO Dialect pro-

Section 7
gram
C96
Section 2 Introduction to ISO Dialect
Notes
Siemens Mode

The following conditions apply when Siemens mode is active:

Siemens G functions are interpreted on the control by default.

It is not possible to extend the Siemens programming system
with ISO Dialect functions because some of the G functions
have different meanings.

ISO Dialect mode

The following conditions apply when ISO Dialect mode is active:

Only ISO dialect G codes can be programmed, not Siemens G
functions.

It is not possible to use a mixture of ISO Dialect code and Sie-
mens code in the same NC block.

If further Siemens functions are to be used, it will be necessary
to switch to Siemens mode first.
Selection of G code system A, B, C

ISO dialect T distinguishes between G code A, B, C. G code system
B is the default setting

G code system A

If G code system A is active, G91 is not available. In this case, incre-
mental axes movement for axis X and Z is programmed by address
U and W. U and W are not available as axis designation in this case
resulting in an axes number of 6
Address H is used for programming incremental movement of the C
axis in G code system A.

Canned cycles of G code A, B, C
All three G code groups have a set of canned cycles but the G code
names given to the canned cycles are different to the G code A, B,
C.

Notice
If not otherwise noted, the manual in hand describes G code system
B.

C96
Notes
The following two G functions are used to switch between Siemens Mode
and ISO dialect Mode:

G290 - Siemens NC programming language active

G291 - ISO Dialect NC programming language active
1
1 In ISO dialect, you will see ISO in top left hand corner
C96
Notes
When writing the NC program the two G functions are placed at the top
and bottom of the program
G291 ;;ISO dialect Mode

G00 G90 G95 G40
G20 G18
G92 S2500
T1
...
...
...
...
G00 G40 Z0.0787
X6.0 Z6.0
G290 ;;Siemens mode
M30
1
1 In ISO dialect, you will see ISO in top left hand corner
1RWHLI\RXSUHVV³5(6(7ÉXWWRQ

halfway through running an NC program, the control will revert back to Sie-
mens mode, as G290 is the default code.
C96
Section 4 ISO Dialect turning addresses
Notes
These are the different addresses that are used in ISO dialect.
Address Meaning
F Feed G94 (mm/inch per min)
F Feed G95 (mm/inch per rev)
F Thread pitch
C Chamfer
R Radius
Q
I, K Interpolation parameters
X G4 Time unit
A Contour Angle

C96
Section 5 Turning G codes
Notes
Here is a list of ISO dialect G codes that are fundamentally different to G
functions in Siemens mode.

Function

Programming
G02/G03 G90 X.. Z.. I.. J.. K.. F.. Absolute end point
Or
G02/G03 G91 X.. Z.. I.. J.. K.. F.. Incremental end point
Or
G02/G03 X.. Z.. R.. F.. Radius of arc

Dwell time G4

Function
hole
In the feed per minute mode (G94) the dwell time unit is in seconds,
while in the feed per revolution (G95) the dwell time unit is in spindle
revolutions.

Programming
G4 G94 X.. X = Time
Or
G4 G95 X.. X = Rotations

C96
Notes
Tool length offset (G43, G44, G49)

Function
The tool length offset function adds or subtracts the amount stored in
the tool offset data memory to or from the Z coordinate values speci-
fied in the program to offset the programmed paths according to the
length of a cutting tool.

Commands
In the execution of the tool length offset function, addition or subtrac-
tion of the offset data is determined by the specified G code and the
direction of offset by the H code.

Programming
**=«+« ;;tool offset is added to Z axis position
Or
**=«+« ;;tool offset is subtracted from Z axis position
Or
G49 ;;cancels the tool offset mode

Return value (G98, G99)

Function
When using canned cycles, the retraction level for the Z axis is deter-
mined through G98/G99. G98/G99 are modal G codes. G98 is usu-
ally set as power-on default.

Programming
**=«5«)
Or
**=«5«)
C96
Notes
Constant cutting rate G96 G97

Function
The spindle will be programmed in constant surface speed (m/min)
and the feedrate will be REV/MIN.
G96 is usually used when turning.

Programming
G96 S.. F..

Note: as the tool get closer to the
centre line the spindle speed will
increase. As the tool gets further
away from the centre line the spin-
dle speed will decrease,
G97 cancels

C96
Section 6 Enhanced level commands
Notes
Canned cycles (G20 to G94)
note: which G code system is used. (A, B,C)

Function
By using canned cycles, it made easier for the programmer to create
programs. By means of canned cycles, machining operations fre-
quently used can be determined in a single block through a G func-
tion. Normally more than one block is required when operating with-
out canned cycles. Using canned cycles can also shorten the pro-
gram in order to save memory.
The three canned cycles below are what is called four block operation for
one cycle e.g. in-feed, cutting (or threading), retraction, and return.
Description Code A Code B Code C

Straight/taper cutting cycle G90 G77 G20
Straight/taper thread cutting cycle G92 G78 G21
Straight/taper facing cycle G94 G79 G24
Cycles called by G70 to G76 (G code system A and B) perform multi
passes
Cycles called by G72 to G78 (G code system C) perform multi passes.
C96
Notes
Four block operation for one cycle e.g. in-feed, cutting (or threading), re-
traction, and return.
G72 (G code system B) perform multi passes
C96
Notes
Subprogram call up function (M98, M99)

Function
This function can be used when subprograms are stored in the part
program memory, subprograms registered to the memory with pro-
gram numbers assigned can be called up and executed as many
times as required
The created subprograms should be stored in the part program
memory before they are called up.

Commands
M98 ;;Subprogram call up
Pxxxx ;;program number
Lyyyy ;;number of program runs
M99 ;;end of subprogram

Programming
M98 Pyyyyxxxx ;;
Or
M98 Pxxxx Lyyyy ;;

G291 200.mpf
: :
M98 P200 :
G00 G40 Z1.9685 :
: :
: :
: M99
M30
Chamfering and corner rounding commands (R, C)

Function
It is possible to insert chamfering and corner rounding blocks auto-
matically between:
Linear interpolation and linear interpolation
Linear interpolation and circular interpolation
Circular interpolation and linear interpolation
Circular interpolation and circular interpolation

Programming
&« ;;chamfering
5« ;;corner rounding

C96
Notes
An ISO Dialect program using the same basic structure as a Siemens pro-
gram, but using instead a ISO Dialect stock removal cycle (G71).
The program above shown running in auto mode

below: note the ISO in red text.
C96
Notes
The same program shown from the simulation page.
C96

Notes
C96

C83 Tools Turning / Milling functions
1 Brief description
Module objective:

Upon completion of this module you will understand workplane selection, and tool types for driven
tools on a turning machine.

Module description:

The tool offsets L1, L2 and L3 are assigned to the relevant axis with the workplane preparatory func-
tions (G codes). This module explains this relationship, which is important when using driven tools.

Module content:
Workplane selection
Tool types for milling/drilling
Workplane selection
Section 2
Tool types for milling/

drilling Section 3
C83
Section 2 Working Plane Selection
Notes
The right hand rule:

The orientation of the coordinate system relative to the machine depends
on the machine type. The axis directions follow the so-FDOOHG³WKUHH-finger-
UXOH´RIWKHULJKWKDQG
The thumb points in the +X direction
The index finger points in the +Y direction
The middle finger points in the +Z direction
Turning coordinate system.

Appling the right hand rule to a turning machine.
C83
Notes
Turning operations are programmed in the G18 plane.
Drilling & milling operations at the end face of the turned part are pro-
grammed in the G17 plane that the offset is applied correctly.

Drilling & milling operations at the peripheral surface of the turned part
are programmed in the G19 plane that the offset is applied correctly
C83
Notes
This is how the axis are assigned from MILLING to TURNING under
ISO STANDARDS.

Make a note of axis assigned to Length1 & Length2 for Turning.
1
2
3
1 A turning machine has no Y axis, the default plane is ZX (G18). In
the case of turning tools the offset L1 is applied to X
2 With G17 on a turning machine, there is no Y axis. Compensation
L3 is therefore not required.
3 With G19 on a turning machine, there is no Y axis, in the case of
a turning tool L2 is then assigned to the Z axis.
C83
Notes
Typical program using G17 plane drilling in the X/Y axis plane
G00 G90 G95 G40 G17

LIMS=2500
G54
T1 D1 ;;CALL DRILL TOOL
G94 S2=1000 F150 M2=03 ;;START SPINDLE
G00 X0.0 Z2.0 ;;RAPID TO SAFE POSITION
G01 Z-10.0 ;;DRILL Z-10.0
Z2.0 ;;RAPID TO SAFE POSITION
G00 X150.0 Z150.0 ;;TOOL CHANGE POSITION
G18 ;;SET PLANE TO DEFAULT
M30
Typical program using G19 plane drilling in the Y/Z axis plane
G00 G90 G95 G40 G19

LIMS=2500
G54
T2 D1 ;;CALL DRILL TOOL
G95 S2=1000 F0.15 M2=03 ;;START SPINDLE FOR LIVE TOOLING
G00 X20.0 Z2.0 ;;RAPID TO SAFE POSITION
Z-30.0 ;;RAPID TO SAFE POSITION
G01 X10.0 ;;DRILL X10.0
G00 X20.0 ;;RAPID TO SAFE POSITION
Z2.0 ;;RAPID TO SAFE POSITION
G00 X150.0 Z150.0 ;;TOOL CHANGE POSITION
G18 ;;SET PLANE TO DEFAULT
The same planes apply when milling, the first part of any drilling or milling
cycle is the infeed direction (or movement).
C83
Section 3 Tool types for milling/drilling
Notes
When creating a drilling / milling tool you have to be aware of the tool type
that you choose, because the tool type goes hand in hand with the
workplane.

Use the following sequence to create a milling / drilling tool.
C83
Notes
1
1 If you wish to drill in the End Face of your turned component, you
would choose the top softkey as your tool type
2
2 Enter the tool number here followed by the OK soft key
C83
Notes
Please make a note of which GEOMETRY columns are which axis.
4 3
3 This is your X axis offset. Length 2
4 This is your Z axis offset. Length 1
Shown below is a typical program for drilling on the End Face of your
turned component using G17.
C83
Notes
If you wish to drill in the peripheral surface of your turned component,
you would choose the second softkey as your tool type.

Follow the sequence.
5
5 Soft key to choose milling tools on the peripheral face.
Note: this tool type is chosen as long as the configuration of the machine is
set with the turret behind the spindle centre line.
C83
Notes
6
6 Enter the tool number here followed by the OK soft key
When you have selected this tool type, you must remember to use G19 as
your working plane.
When you set the tool offset you must also remember to set the correct
Axis to Length 1 and Length 2 in the Geometry column.
7 8
7 This is your X axis offset. Length 1
8 This is your Z axis offset. Length 2
C83
Notes
Shown below is a typical program for drilling on the peripheral surface of
your turned component using G19.
C83
Notes
When choosing the tool type for Milling, the only difference is the graphi-
cal representation.
9
9 Soft key to choose milling tools
10
10 Soft key to choose the different planes for milling
C83

C8 Pushbutton Tests
Software Version 1.4
1 Brief description
Module objective:

Upon completion of this module you can identify which Machine Control Panel (MCP) is installed and
perform a pushbutton test
Module description:

There are two possibilities currently existing to connect a Machine control panel to the 802D SL CNC.

1. The first variant is to connect an MCP to the (additionally required) MCPA board, section 2.2.
2. The second variant is to connect the MCP to the PLC periphery, section 2.2

The hardware differs between the two variants, the part numbers (MLFB) are given in the respective
sections.

In certain cases it may become necessary to perform a pushbutton test. The objective of the test, is
to determine whether or not a pushbutton / LED on the machine control is defect.
Hardware identification
Hardware interface
Module content:
MCP and MCPA:-
General information. Section 2
MCPA:-
Hardware identification Section 3
Interface signals
MCP:-
Hardware identification Section 4
Interface signals
MCP and MCPA

LED testing Section 5

Section 2 MCP and MCPA versions
2.1 General information. Notes
The following diagram shows the layout of the 802D machine control
panel.

The layout is the same for both of the MCP types.

The CNC functionality is the same for both of the MCP types.

The addressing of the inputs of the MCP differs between MCP types.

The addressing of the customer LED's differs between MCP types.

The input voltage differs between the MCP types.
(MCPA = 5V DC, MCP = 24V DC)
Each pushbutton is assigned a mnemonic identifier.

Example: NC START key is given mnemonic #27
+X key is given mnemonic #17

2.2 MCP/MCPA layout
[VAR]
Jog
Ref Point
Auto
Single Block
MDA
Spindle Left
Spindle Stop
Spindle Right
Reset
Rapid
Cycle Stop
After performing a pushbutton test, it may be found that all pushbuttons
are defective and not just one key or lamp.
In the case where all keys and lamps are not working the MCPA board or
the PP72/48 could be faulty and not necessarily the MCP.
Section 3 MCPA - Hardware identification
To carry out a pushbutton test, it is necessary to differentiate between the Notes
WZR0&3YDULDQWV:KHQYLHZHGIURPWKHIURQWERWK0&3¶VDUHLGHQWLFDOLQ
appearance.

3.1 Identification of MCP connected to MCPA interface card.

Identification can be done visually by simply examining the hardware of the
from the reverse side. The following photograph shows the MCPA
(Machine Control Panel Analogue) version. This method comprises of two
parts, the MCP and the MCPA interface card.
The MCPA interface card is mounted directly on the PCU210.3.
The MCP connects into the MCPA interface card by way of two 37-way
ribbon cables..

The second method of identification is to check the status of PLC Variable
V18001000.7 (P_H_MCPA)-MCPA exists. The control detects the physical
presence of the MCPA and sets this bit=1.

Note:-Plc variable V18001000.7 can be made to change status via the
³3/&VWDWXV´VFUHHQHYHQZKHQWKH0&3$LVSUHVHQW7KLVZLOOEHUHVHWRQ
power Off/On of the control.
Any attempt to write to the variable in the PLC program will result in a
³3/&VWRS´DODUP

Apart from interfacing between the MCP and the PCU210.3, the MCPA
also offers extra functionality such as the controlling of a single analogue
axis and digital I/O. Module C11 explains this in more detail.

Section 3 MCPA - Hardware identification
The following table contains product information for the MCPA. Notes
3.2 Interface signals.
Machine control panel Machine control panel I/F
X1202
X1201
X2 X1
It is important to correctly connect the ribbon cables between the MCP and
the MCPA interface board.
MCP connector X1201 to MCPA Interface board connector X1.
MCP connector X1202 to MCPA Interface board connector X2.

Section 3 MCPA - Interface signals
The MCPA uses PLC variables for the interface signals. These are shown Notes
in the table below. To carry out a pushbutton test these variables are
monitored via the PLC status function of the control or the PLC802
programming tool. Each pushbutton (Key) has been given an mnemonic
identifier ranging from #1 to #27
Pushbutton testing examples based on the above diagram:

NC START Pushbutton.
NC START = mnemonic #27
#27 = V10001003.2
NC STOP Pushbutton
NC STOP = mnemonic #26
#26 = V10001003.1

Due to the update time of the HMI software you should keep the key
pressed in order for the change to register on the screen.
([DPSOH+RZWKHVLJQDOVDUHWHVWHGXVLQJ³3/&6WDWXV´RQWKHFRQWURO
+HUHWKH³1&6WDUWÝDULDEOHV10001003.2=1 indicating that the button is
activated.

Section 4 MCP - Hardware identification
4.1 Identification of MCP connected to a PP72/48 periphery board. Notes
The MCP variant uses a PP72/48 periphery board to interface to the
control.
Due to both variants of MCP looking identical from the front, Identification
is done by visual inspection of the hardware and checking of part numbers.
Variable V18001000.7 can be checked in the PLC status area.
If V18001000.7 = 0, MCP is in use. If V18001000.7 = 1, MCPA is in use.
It must be noted that the variable can be set in the PLC status area
regardless of which type of MCP is fitted. This variable reverts to the
correct status on power Off/ON of the control.
Attempting to change the state of the variable in the PLC program will
Result in a PLC stop alarm.
Periphery board PP72/48
6FC5603-0AD00-0AA1
X111 X1201
X222 X1202
X333
The location of the PP72/48 connectors can be seen above.
The following table contains product information for the MCP.

Section 4 MCP - Interface signals
4.2 Interface signals. Notes
A maximum of three PP modules can be fitted to the 802D sl.
Compatibility must be taken into account before deciding where to connect
the MCP. The following table shows the I/O assignment of an MCP
connected to the first PP module. (PP72/48 plug X111 to MCP plug
X1201and PP72/48 plug X222 to MCP plug X1202)
In this case the I/O addressing will start at 0 (Zero).
3.2 Pushbutton testing examples based on the above diagram

NC START Pushbutton.
NC START = mnemonic #27
#27 = I3.2
NC STOP Pushbutton
NC STOP = mnemonic #26
#26 = I3.1
Due to the update time of the HMI software you should keep the key
pressed in order for the change to register on the screen.
7KHVWDWHRIWKHLQSXWVFDQEHFKHFNHGYLD³7KH3/&VWDWXV´DUHDRIWKH
FRQWURO7KHDERYHH[DPSOHVKRZVWKDWWKH³1&VWDUWÉXWWRQLVDFWLYDWHG

Section 5 MCPA and MCP LED testing
Note:- &DUHPXVWEHWDNHQZKHQWHVWLQJWKH/('¶V Notes
The user PLC program must be consulted to ensure that artificially
changing the state of an output does not result in any unwanted machine
movement.

7KH³&KDQJHÍXQFWLRQLQWKH³3/&VWDWXV´DUHDRIWKHFRQWUROZLOOQRWDOORZ
the changing of an output that is assigned in the PLC program. The PLC
program itself will have to be edited to test the output.
Many machine tool builders have a special test function for the purpose of
VDIHO\WHVWLQJWKH/('¶VDQGODPSVRIDPDFKLQH

2WKHUPHWKRGVRIWHVWLQJWKHVWDWXVRIDSXVKEXWWRQDUH³6WDWXVOLVW´RQWKH
FRQWURODQG3URJUDPPLQJ7RRO3/&VRIWZDUHZLWKWKHIXQFWLRQV³&KDUW
VWDWXV´DQG³3URJUDPVWDWXV
Module C28 offers more information of these methods.


C9 LED Diagnosis²Drive
1 Brief description
Module objective:

Upon completion of this module you can locate the status LED's and determine the module status.
Module description:

The 802D SL controller has extensive diagnostic possibilities, one of which is the LED diagnostic on
the drive modules.
It is possible using the LED status to determine quickly the hardware status of the drive boards.
Before investigating faults using external diagnostic tools (HMI alarm, Starter etc) a status should first
be taken of the drive LED's.
Module content:
Locating the status LED's

Status of Motor Module LED's
Status of Active Line Module LED's
Status of Smart Line Module LED's
6WDWXVRI6PDUW/LQH0RGXOHN:/('
V
Locating the status

LED's
Section 2
Status of LED's:-

Motor Modules, Section 3
ALM & SLM (> 16 Kw)
Status of LED's:-

Section 4
SLM (< 16Kw)

Section 2 Locating the status LED's
/RFDWLQJWKHVWDWXV/('¶V Notes
As can be seen from the picture below, the status LED´s are always
located in the same place on the drive modules.
Ready
DC Link
6WDWXVRI/('¶V-Motor Modules, ALM &

Section 3 SLM > 16Kw.
00/('
V$/0/('V6/0/('VN:
LED´s for:
Motor Module
Active Line Module
Smart Line MRGXOHN:

The above modules share identical LED functions, therefore the table
below can be used for these module types.
In the case where a fault diagnosis is not possible a status of the LED´s
should be given to the OEM or to Siemens service personnel.
(Only when module is ready)

Section 4 Status of LEDs:- SLM < 16kW
Notes
4.1 SLM LED´s < 16kW
LED´s for:-

Smart Line Module < 16 Kw

The above module does not have DriveCliq capability, therefore the LED
functionality is different. The table below decribes the meaning of the
VWDWXV/('¶V
In the case where a fault diagnosis is not possible a status of the LED´s
in the case where a fault diagnosis is not possible a status of the LED´s


C10 LED Diagnosis-HMI
1 Brief description
Module objective:

Upon completion of this module you can locate the status LED's and determine the status of the CNC
controller
Module description:

The 802D SL controller has extensive diagnostic possibilities, one of which is the LED diagnostic on
the CNC Controller.
It is possible using the LED status to determine quickly the hardware status of the CNC controller.
Before investigating faults using external diagnostic tools (HMI alarm, Starter etc) a status should first
be taken of the controller LED's.
Module content:
Locating the Status LED's

Status of CNC Controller LED's
Locating the Status

LED's.
Section 2
Status of CNC

Controller LED's. Section 3

Section 2 Locating the Status LED's

Notes
2.1 Locating the Status LED's
As can bee seen from the picture below, the status LED´s are located
above the LCD display on the right hand side, behind the plastic cover.
Section 3 Status of CNC Controller LED's
3.1 Status of CNC Controller LED's
In normal run condition:- 7KHJUHHQ³5'<´/('LVOLWFRQVWDQWO\

7KH\HOORZ³1&´/('IODVKHVDWDSSUR[+]
7KH\HOORZ³&)´/('ZLOOIODVKZKHQWKH&)FDUG
(Internal or external) is accessed.

In the case of ERR (red) a further investigation is required, using internal
and external diagnostic tools in general.
Example:- $ODUP³3/&VWRS´FDQEHFDXVHGE\DGGUHVVLQJD
non-H[LVWHQWLQSXW,QWKLVFDVHWKH³(55´/('ZRXOGEHSHUPDQHQWO\OLW
The cause of the error would need to be investigated with the
3URJUDPPLQJWRRO³3/&´


C11 MCPA interface board
1 Brief description
Module objective:

Upon completion of this module you can:-
Locate the MCPA board in the system
Perform a hardware diagnosis of the analogue spindle speed setpoint.
Test the digital inputs and outputs.
Module description:

The MCPA board can be used to drive an analogue spindle and also to connect an MCP. Diagnosing
MCP signals can be carried out with the help of module C8 (pushbutton test).
When hardware is not correctly commissioned it can result in damage to hardware, in this case the
MCPA board itself.

Module content:
Identification of MCPA in the system.

Analogue spindle interface test.
Digital Input and output tests.

Identification of MCPA

in the system Section 2
Analogue spindle
Interface test Section 3
Digital input and output

signal tests. Section 4
Section 2 Identification of MCPA in the system
3.1 Identification of MCPA interface card. Notes
Identification can be done visually by simply examining the hardware of the
from the reverse side. The following photograph shows the MCPA
(Machine Control Panel Analogue) version. This method comprises of two
parts, the MCP and the MCPA interface card.
The MCPA interface card is mounted directly on the PCU210.3.
The MCP connects into the MCPA interface card by way of two 37-way
ribbon cables.
MCPA interface
Board.
3.2 Location and description of connectors.
MCPA interface board brief

description of connectors:-

X1-MCP I/O signals (X1201 of MCP)
X2-MCP I/O signals (X1202 of MCP)

X1020-Digital NC inputs
X1021-Digital NC outputs
X701

X701-Analogue spindle control
(Speed set-point, enables &
direction)
X1020 X1021
The MCPA requires a 24V DC
supply. This is done via connectors:-
X1021:- Pin 1 = +24V, Pin 10 = 0V
X1020:- Pin 10 = 0V
X2 X1
Section 3 Analogue spindle signal test.
3.1 Machine Data Notes
The operation of the analogue spindle is dependant on various machine
data.
One machine data in particular will determine the correct method of
proceeding to test the signals on the analogue spindle connector X701.
The machine data in question is Axis Machine Data 30134-
IS_UNIPOLAR_OUTPUT[0].
7RILQGWKLVPDFKLQHGDWDVHOHFWWKH³6\VWHP´DUHDZLWKWKHIROORZLQJ
simultaneous key presses:-
+
The machine data screen is located with the following softkey selection:-
The correct axis must be selected.
In this example the Spindle (SP) axis is selected.
7KH³ILQGÍXQFWLRQLVDYDLODEOHWRORFDWHWKHGHVLUHGPDFKLQHGDWD
The value of the machine data 30134 can now be seen. Notes
There are 3 possible options for Machine Data 30134, these options and
the effect they have on the analogue spindle out put are described in the
following pages.

3.2 Analogue spindle connector (X701).
The MCPA interface board has a 9-pin male D type connector for the
outputting of the spindle signals. This connector is labeled as X701.
The following table shows the functionality of the pins of connector X701.
Pin Name Function/Description
1 Analogue +/-10v Analogue output reference signal.

OUT Example:-T56 of Simodrive system.
2 Not used
3 Uni-Dir2 +24v Digital output for Unipolar direction 1
4 Uni-Dir1 +24v Digital output for Unipolar direction 2
5 Enable 1 Normally open, volt free drive enable contact.

Example:-T65 of Simodrive system. (Used with Enable 2)
6 Analogue 0v Analogue output reference signal.
OUT Example:-T14 of Simodrive system.
7 Not used
8 Not used
9 Enable 2 Normally open, volt free drive enable contact.

Example:-T9 of Simodrive system. (Used with Enable 1)
3.3 Testing the signals:-Machine Data 30134=0. Notes
Example:-6HOHFW³0'$´PRGHRQWKHFRQWUROOHUDQGW\SHLQDVSLQGOH
direction and speed.

MDA MDA

In our example M3 S50 (Spindle clockwise at 50 rpm)
G4 F20 (Dwell for 20 seconds)
M30 (Program end)

3UHVV³1&6WDUW´KHVSLQGOHZLOOUXQFORFNZLVHDWUSPIRUVHFRQGV
then halt.

NC Start

Due to the type of connector, it is more convenient to measure the signals
at the drive.

The expected signals for this situation will be:-
A positive voltage at X701 pin 1 with respect to pin 6.
The normally open contact between X701 pins 5 & 9
to be closed.

Note 1:- The polarity of the reference voltage between pins 1 & 6 can be
reversed by Axis Machine Data 32100 AX_MOTION_DIR. If the default
value of 1 is entered, the polarity of X701 pin 1 will be positive for a
clockwise spindle command (M3). A value of ±1 for machine data 32100
would cause X701 pin 1 to be negative for a clockwise spindle command.

Note 2:-The voltage level of pins 1 & 6 is determined by the commanded
speed and Axis Machine Data 32250 RATED_OUTVAL[0] & 32260
RATED_VELO[0].
Machine Data 32250 is a percentage of the maximum analogue output
value of 10V (100%=10V, 50%=5V etc)
Machine Data 32260 is the maximum speed of the spindle. At this speed
the reference output on pins 1 & 6 will be at the level set in Machine Data
32250. At other commanded speeds the reference voltage will be
Proportionate to this.
In our example with the following machine data:- Notes

30134 = 0
32100 = 1
32250 = 100
32260 = 500

The voltage at X701 pins 1 & 6 would be +1 Volt.
This is because the value of machine data 32250 = 100, this sets the
reference voltage to 10V at the speed in machine data 32260 (500 RPM)
The commanded speed (50 RPM) is 10% of the max speed set in machine
data 32260 (500 RPM). Therefore 10% of the reference value (1 Volt) is
output.
If a spindle counter-clockwise (M04) command was programmed the
Polarity of the voltage at X701 pins 1 & 6 would be reversed.
3.4 Testing the signals:-Machine Data 30134=1

This setting only outputs a positive voltage (0 to 10v) on X701 pins 1 & 6
regardless of the programmed direction (M03 or M04).

To facilitate a change in direction:-
X701 pin 3 outputs +24V with the M04 command.
This signal can be utilised to reverse the spindle via relays or contactors
which is necessary on certain types of drives.

X701 pin 4 will output +24V for both directions and can be used for enable
purposes.

These tests assume Machine Data 32100 AX_MOTION_DIR = 1.
Changing 32100 = -1 will invert the behaviour of X701 pin 3

The signals on pins 3 & 4 should be measured to the 0V of MCPA
Connector X1021 pin 10.
3.5 Testing the signals:-Machine Data 30134=2

This setting only outputs a positive voltage (0 to 10v) on X701 pins 1 & 6
regardless of the programmed direction (M03 or M04).

To facilitate a change in direction:-

These signals can be utilised to reverse the spindle via relays or
contactors which is necessary on certain types of drives.

The signals output on pins 3 & 4 should be measured to the 0V of MCPA

These tests assume Machine Data 32100 AX_MOTION_DIR = 1.
Changing 32100 = -1 will invert the behaviour of X701 pins 3 & 4

The signals on pins 3 & 4 should be measured to the 0V of MCPA
Section 4 Digital input and output signal tests.
4.1 Digital input testing. Notes
Before testing can proceed the physical location of the inputs needs to be
known.
These are via connector X1020 on the MCPA board. (See page 2 section 3.2)

Connector X1020 pin assignment
Pin Description Designation
1 +24V DC
2 Digital input 0 $A_IN[9]
10 0V DC
There are eight inputs available, each one has a variable assigned to it. The
first variable starts at number 9. The variables 1 to 8 are reserved for the
PCU210.3/Sinamics (Connectors X20 and X21)
The operation of the Inputs depends on the setting of certain General
Machine Data. Locate the machine data screen by referring to Section 3.1
machine data, page 3. The required machine data are accessed with the
³*HQHUDO0'´VRIWNH\

&XUVRUWRRUXVHWKH³)LQGÍXQFWLRQWRORFDWHWKHFRUUHFWPDFKLQHGDWD-
10350 FAST_NUM_DIG_INPUTS = 2

The number of bytes available for use with fast digital inputs, this is set to 2
by default. The first byte is used for the PCU210.3/Sinamics.
Attempting to use digital inputs outside of the range set will result in alarm:-
³&KDQQHOEORFNGLJLWDOLQSXWFRPSDUDWRUQRxx QRWDFWLYDWHG´
:KHUH³xx´ WKHGLJLWDOLQSXWQXPEHU

10366 HW_ASSIGN_DIG_FASTIN[0] = 00010101H

The hardware (MCPA) has to be assigned to the local bus by entering the
above value. (Default value = 00H).

7RWHVWDQ,QSXWVHOHFW³0'$´PRGHDQGW\SHWKHIROORZLQJ-
(Not he text in brackets)

MDA

PG: (Label)
R1=$A_IN[9] (Read the state of the digital input on X1020 pin 2 to R1)
*272%3*6HDUFKEDFNZDUGVWKURXJKWKHSURJUDPWRWKHODEHO³3*´

3UHVVWKH³1&6WDUWÉXWWRQ
The program will loop continuously allowing the state of the digital input to Notes
be monitored via R parameter R1.
&KHFNLQJWKHVWDWHRIWKHLQSXWRQWKH³5YDULDEOH´VFUHHQ
The value of R1 = 1 which indicates that X1020 pin 2 should be +24V
when measured to X1020 pin 10.
If the voltage was not present it would suggest a faulty MCPA board.
4.2 Digital output testing. Notes
Before testing can proceed the physical location of the outputs needs to be
known.
These are via connector X1021 on the MCPA board. (See page 2 section 3.2)

Connector X1021 pin assignment
Pin Description Designation
1
2 Digital output 0 $A_OUT[9]
10 0V DC
There are eight outputs available, each one has a variable assigned to it.
The first variable starts at number 9. The variables 1 to 8 are reserved for
the PCU210.3/Sinamics (Connectors X20 and X21)
The operation of the outputs depends on the setting of certain General
Machine Data. Locate the machine data screen by referring to Section 3.1
machine data, page 3. The required machine data are accessed with the
³*HQHUDO0'´VRIWNH\

&XUVRUWRRUXVHWKH³)LQGÍXQFWLRQWRORFDWHWKHFRUUHFWPDFKLQHGDWD-
10360 FAST_NUM_DIG_OUTPUTS = 2

The number of bytes available for use with fast digital outputs, this is set to
2 by default. The first byte is used for the PCU210.3/Sinamics.
Attempting to use digital outputs outside of the range set will result in alarm:
-
³&KDQQHOEORFNGLJLWDORXWSXWQRxx QRWDFWLYDWHG´
:KHUH³xx´ WKHGLJLWDORXWSXWQXPEHU

10368 HW_ASSIGN_DIG_FASTOUT[0] = 00010101H

The hardware (MCPA) has to be assigned to the local bus by entering the
above value. (Default value = 00H).
7RWHVWWKHVWDWHRIDQRXWSXWVHOHFW³0'$´PRGHDQGW\SHWKHIROORZLQJ-
(Not the text in brackets!)

MDA

PG: (Label)
R1=$A_OUT[9] (Read the state of the digital output on X1021 pin 2 to R1)
*272%3*6HDUFKEDFNZDUGVWKURXJKWKHSURJUDPWRWKHODEHO³3*´

3UHVVWKH³1&6WDUWÉXWWRQ

Notes
The program will loop continuously allowing the state of the digital output to
be monitored via R parameter R1.
&KHFNLQJWKHVWDWHRIWKHRXWSXWRQWKH³5YDULDEOH´VFUHHQ-
The value of R1 = 1 which indicates that X1021 pin 2 should be +24V
when measured to X1021 pin 10.
If the voltage was not present it would suggest a faulty MCPA board.
7KHVWDWHRIDGLJLWDORXWSXWFDQEHVHWZLWK³0'$´PRGH Notes
The above program will switch the digital output on X1021 pin 2 on and off
every five seconds (G4F5 = 5 second dwell).
This can be checked with a meter.

Note:-Care should be taken on machinery when switching outputs in
this fashion, unwanted movements may occur which can cause
damage to the machinery and personnel.

Blank page Notes

C17 Save Data
1 Brief description
Module objective:

Upon completion of this module you can Save Data which is stored in the volatile data to the internal
Flash memory of the CNC Controller.
Module description:

The 802D SL controller executes with data which is stored in volatile memory. This volatile memory is
retained using a GoldCap capacitor. If the machine is powered off for more than 50 hours, the data
which is stored in the volatile memory can be lost. It is therefore necessary to Save this data to Flash
memory when the machine is switched off for periods which are longer than 50 hours. When neces-
sary this previously saved data can be reloaded to the volatile memory from the Flash memory.
All data excluding the PLC program are saved, the PLC is stored always in non-volatile memory
(Flash memory) and will not be lost upon dissipation of the GoldCap.
Module content:
Performing a Data Save
Performing a Data
Save
Section 2
Section 2 Performing a Save Data
Notes
2.1 Performing a Save Data
7RSHUIRUPD6DYLQJRIGDWD\RXKDYHWRHQWHUWKH³6\VWHP$UHD´7RHQ
WHUWKH³6\VWHP$UHD´SURFHHGDVIROORZV

On NC Keyboard ² Press the key SHIFT + ALARM
Keyboard (upright)
Keyboard (broad)
7RSHUIRUPD³6DYH'DWD´WKHSDVVZRUG³&86720(5´KDVWREHVHW

Password
CUSTOMER
To Save Data
Section 2 Performing a Save Data
Notes
Confirm with OK to save data..

To Save Data
Confirm with OK
It is also possible to see in the above picture, which data will be saved.


C18 Restore Saved Data
1 Brief description
Module objective:

Upon completion of this module you can restore the data which is stored in the flash memory to the
internal SRAM (active, volatile) memory of the CNC controller.
See hand book module C17 Save data
Module description:

The 802D SL controller executes with data which is stored in volatile memory. This volatile memory is
retained using a GoldCap capacitor. If the machine is powered off for more than 50 hours, the data
which is stored in the volatile memory can be lost. It is therefore necessary to Save this data to Flash
memory when the machine is switched off for periods which are longer than 50 hours. When neces-
sary this previously saved data can be reloaded to the volatile memory from the Flash memory.
All data excluding the PLC program are saved, the PLC is stored always in non-volatile memory
(Flash memory) and will not be lost upon dissipation of the GoldCap.
This module describes the methods of restoring the previously saved data.
See hand book module C17 Save data
Module content:
Performing a Restore of saved data
Performing a Restore
of saved data
Section 2
Section 2 Restoring Saved Data
2.1 Restoring Saved Data Notes

7KH³6DYHGGDWD´FDQEHUHVWRUHGLQVHYHUDOZD\V

SELECT picture at Startup
Automatic (in case of data loss)

The system can detect loss of data, upon data loss the saved data will be
loaded into the volatile memory automatically.
Saved data can be restored by the user at any time by pressing the SE-
LECT key when prompted at Startup time of the control.
The following picture then appears²one of the two will appear dependant
upon which password is activated.
7KHDODUPLQGLFDWHVWRWKHRSHUDWRUWKDW³VDYHGGDWD´KDVEHHQ
loaded, this alarm can be acknowledged with the reset key.
CUSTOMER Password set
Startup Menu
Normal Startup
Reload saved user data
Software update
EVENING²SUNRISE Password set
Startup Menu
Normal Startup
Startup with default data
PLC Stop
PLC overall reset / default PLC program
HMI Startup with default data
Remove drive data
Remove drive data/default data
Software update

C19 External data Backup + Restore with CF card
1 Brief description
Module objective:

Upon completion of this module you can save to a Compact flash card, a complete backup of the
control.
Module description:

Due to component defect, it may become necessary to exchange the CNC system. In such a case
WKH³6DYHGGDWDÍXQFWLRQLVQRWRIDQ\XVH,WEHFRPHVQHFHVVDU\WRSUHYLRXVO\VWRUHDFRPSOHWH
backup of the controls machine specific data. Saving the data is described in this module and also
loading the data back to a replacement control.
Module content:
Saving all data to CF Card

Automatic save of all data to CF card
Restoring data from CF card

Saving all data to CF

Card Section 2
Automatic save of all

Section 3
data to CF card
Restoring data from

Section 4
CF card
Section 2 Saving All data to Compact Flash card
Notes
2.1 Saving All data to Compact Flash card
All data can be saved to a CF card using Copy and Paste functionality. To
use the feature a CF card should be inserted into the controller, as can be
seen below:

The CF card can be up to 2GB, and should be formatted using the FAT16
or FAT32 file system.

To make a backup of the machine configuration, that the controller can be
restored to it's original state requires that two archives should be saved to
the CF card. These two files can be saved to the card in the SYSTEM area
of the control. i.e. NC/PLC archive and HMI archive
The SYSTEM area of the control is reached by pressing the key : SHIFT +
ALARM.
The entry point for saving data is through softkey Start-up files, see picture
below:

Section 2 Saving all data to compact flash card
Notes
The following display can then be seen:
The two files previously mentioned can be saved by copying the contents
of the HMI and the NC/PLC directories into two archives.
The following picture describes this process:
Move cursor to NC/

PLC directory and
press SK Copy
The destination should now be selected and the Paste function can be
used to save the files to the respective card. The destination is the
³&XVWRPHU&)FDUG´
Section 2 Saving all data to compact flash card
Notes
After pressing Paste

softkey change file
name to
e.g. NC_PLC.ARC and
confirm with OK softkey
The above should be repeated for the HMI archive.

The two archives should be now visible on the CF card. The CF card
should now be removed from the system and stored safely.
To reflect the newest changes this process should be carried out on a
regular basis.
Both archives saved to

CF, card can now be re-
moved and stored safely.
Section 3 Automatic save of all data to CF card
Notes
3.1 Automatic save of all data to CF card
Complete save of all system data can also be implemented by pressing
[CTRL] + [S] at any time. This will automatically create a complete archive of
all NC & PLC data, and HMI data in two archive files and write these files
onto the CF Card. The archives are created with default names.

802dslibnhmi.arc
802dslibnnc.arc

The file creation will overwrite any existing files of that name without requir-
ing confirmation.

The only pre-requisite for this procedure is that the protection level password
must be set to a minimum of level 3 (User level)

After the file creation procedure is complete, an NCK reset is performed.

DO NOT remove the CF card until this is completed, otherwise system data
corruption will occur.
Section 4 Restoring All data from Compact flash card
Notes
4.1 Restoring All data from Compact flash card
In the case of component exchange it will be necessary to reload the previ-
ously saved archives to achieve a functional machine.

The following steps should be carried out in order to reload the data previ-
ously stored on the CF card.

The controller should first be switched on and the password for the SER-
VICE should be set: The password for a new CNC component is always
WKHGHIDXOW³(9(1,1*´WKLVVKRXOGEHFKDQJHGDIWHUQHZLQVWDOODWLRQWR
prevent mishandling of the system in the future.
Once the password is set the system should be switched OFF and ON and
the Startup menu entered with the SELECT key when prompted.
See picture below:

Startup Menu
Normal Startup
Startup with default data
PLC Stop
PLC overall reset / default PLC program
HMI Startup with default data
Remove drive data
Remove drive data/default data
Software update
&KRRVHPHQXRSWLRQ³6WDUWXSZLWKGHIDXOWGDWD´DQGFRQILUPZLWKWKH
ENTER key.
The control will now re-start, wait until the control is finished starting up
and once again enter the SERVICE password.
<RXVKRXOGVHHWKHPHVVDJH³6WDQGDUGPDFKLQHGDWDLVORDGHG´
Using copy from CF card and paste to CNC the backup data can be re-
stored to the control. See the following diagrams:

Notes
Select HMI archive and

with COPY softkey pre-
pare for paste operation
to CNC
Select HMI directory

DQGSUHVV³SDVWH´
softkey
Notes
Confirm the dialog box with the OK softkey, the HMI archive will now be
read into the controller.
During this reading in process the controller will reboot once, the process
will take approximately 1 minute to complete.
This procedure should be repeated for the NC/PLC archive, the CNC will
reboot more times and the process takes approximately 4 minutes to com-
plete. The NC_PLC archive should be copied to the NC PLC directory and
not the HMI.

Upon completion of this process the machine should be functional again.

Note: The HMI archive should be read in first because the specific PLC
alarms are in the NC/PLC archive.

C28 Diagnose PLC Program
1 Brief description
Module objective:

Upon completion of this module you can use the built-in PLC program displays to diagnose faults.
Module description:

The 802D SL controller has extensive diagnostic possibilities, one of which is the online display of the
PLC program.
It is possible using this function to quickly evaluate logic faults or external switching faults on the ma-
chine. To use this function effectively previous knowledge of PLC programming is advantageous.

Module content:
Locating the PLC Program displays

Navigating the displays
Program status ON/OFF
Searching
Cross referencing
Locating the PLC Pro-

gram displays
Section 2
Navigating the displays

Section 3
Program status ON/

Section 4
OFF
Searching
Section 5
Cross referencing
Section 6
Section 2 Locating the PLC Program displays
2.1 Locating the PLC Program displays Notes
7KH3/&3URJUDPGLVSOD\FDQEHIRXQGLQWKH³6<67(0DUHD´7KHGLV
SOD\VDUHRQO\DYDLODEOHZKHQWKH³6(59,&(´SDVVZRUGLVVHWRUKLJKHU
7RHQWHUWKH³6<67(0´DUHDSUHVVWKHNH\³6+,)7$/$50´

In the system area you will see the softkey PLC, upon pressing the softkey
PLC the following picture is displayed:
When entering the PLC area, the default for the control is to open the
³3URJUDPOLVW´SLFWXUH7KLVIXQFWLRQLVH[SODLQHGLQWKHKDQGERRNPRGXOH
C33.
7KH3/&3URJUDPGLVSOD\VFDQEHIRXQGE\SUHVVLQJWKHVRIWNH\³3/&
3URJUDP´
The following picture can be seen:
Section 3 Navigating the displays
3.1 Navigating the displays Notes
Project name, Version , Cycle time, Processing time.
Notes
Status >> Bits, Bytes, Words, DWords with the possibility to
change
Overview Input, Output, Marker area with the possibility to

change
Notes
Status >> logic online/offline

Define which block

with softkey
³3URJUDPEORFN´
Status >> logic online/offline as Window 1

'HILQHZKLFKEORFNZLWKVRIWNH\³3URJUDPEORFN´
Notes
Locator >> Where is it used? And as what?
Section 4 Program status ON/OFF
4.1 Program status ON/OFF
With Program status ON, a real-time picture can be seen of the logic con-
trolling the machine.
switch OFF to

conserve proces-
sor resources
Section 5 Searching
Notes
5.1 Searching
Search / Find: the function can be used context sensitive to find operands
or symbols located in the body of the PLC program or cross reference
table.
Section 6 Cross referencing
6.1 Cross referencing
Find all occurrences of operands in the PLC program


C31 Diagnose PLC alarm
1 Brief description
Module objective:

Upon completion of this module you can use the built-in PLC program displays to diagnose a PLC
generated fault.
Module description:

The 802D SL controller has extensive diagnostic possibilities, one of which is the online display of the
PLC program.
It is possible using this function to quickly find the source of a PLC generated fault, and quickly re-
solve an external fault on the machine. e.g. faulty sensor.
Module content:
Structure of an alarm

Function of alarm
Cross referencing
Structure of an alarm

Section 2
Function of alarm

Section 3
Cross referencing
Section 4
Section 2 Structure of an alarm
2.1 Structure of an alarm Notes
To identify external faults from the generated PLC fault, it is necessary to
understand the structure of the alarm.

Structure:

700000 Hydraulic pressure low

700001 Tailstock not in position

700002 Axis %d in parked position
Axis %d in parked position ²²- Axis 1 in parked position

Axis 2 in parked position
Alarm Num- Variable = 1 Alarm Text
Alarm Number PLC Signal PLC variable NC MD alarm Text File
configuration
700000 16000000.0 16001000 14516[0] Alarm 1
700001 16000000.1 16001004 14516[1] Alarm 2
700002 16000000.2 16001008 14516[2] Alarm 3
700003 16000000.3 16001012 14516[3] Alarm 4
700004 16000000.4 16001016 14516[4] Alarm 5
700005 16000000.5 16001020 14516[5] Alarm 6
700006 16000000.6 16001024 14516[6] Alarm 7
700007 16000000.7 16001028 14516[7] Alarm 8
700008 16000001.0 16001032 14516[8] Alarm 9
700009 16000001.1 16001036 14516[9] Alarm 10
700010 16000001.1 16001040 14516[10] Alarm 11
700011 16000001.1 16001044 14516[11] Alarm 12
700012 16000001.1 16001048 14516[12] Alarm 13
.. .. .. .. ..
.. .. .. .. ..
.. .. .. .. ..
.. .. .. .. ..
700063 16000007.7 16001252 14516[63] Alarm 63
Variable definition

%d Decimal value displayed
%x Hexadecimal value displayed
%b Binary value displayed
%o Octal value is displayed
%u Unsigned integer is displayed
%f Floating point number is displayed
PLC Signal
The alarm 700000 is generated with the corresponding PLC signal, the
reaction from the NC is defined in the NC machine data 14516[index].
Section 3 Function of alarm
3.1 Function of alarm Notes
Alarms are generated for a purpose, the purpose is primarily to protect the
machine operator in the case of a dangerous situation and secondly to
protect the machine from damage.

To cater for the above two cases we can react in two ways:

1) Pure PLC reaction
2) PLC >> NC reaction

The first is to use the alarm to warn the operator of a problem, e.g. coolant
is low in the machine. In such a case the axis can be prevented from mov-
ing by various disable signals in the PLC interface.

The second case is to configure the alarm in such a way that the NC can
react itself. e.g. in the case of an alarm NC start can be automatically in-
hibited.

The possibilities are listed below:

MD 14516[index] Meaning
Bit 0 NC Start inhibit
Bit 1 Read-in disable
Bit 2 Feed disable for all axis
Bit 3 Emergency stop
Bit 4 PLC Stop
Bit 5
Bit 6 Cancel with Delete key
Bit 7 Power on
Section 4 Cross reference
4.1 Cross reference Notes
It may become necessary to track an alarm to it's source.
A logic condition generates the alarm, the logic condition has to be found
in the PLC program and diagnosed using status.
To find the logic, the cross reference function should be used.

See the following picture:
Result

C37 Alarm Structure NC
1 Brief description
Module objective:

Upon completion of this module you will be able to identify an NC alarm.
Module description:

The 802D SL controller has extensive diagnostic possibilities, one of which is the display of the active
NC alarm.
With this knowledge you can find in the diagnostic guide, and interpret the fault.
Module content:
Locate the alarm display

Find the alarm description in the diagnostic guide
Locate the alarm dis-

play
Section 2
Find the alarm descrip-

tion in the diagnostic Section 3
guide
Section 2 Locate the alarm display
Notes
2.1 Locate the alarm display
The alarm display has to be selected in order to interpret the active alarm.
The display can be selected with the ALARM key on the NC keyboard. The
following display will be seen :

The alarm number determines whether an alarm is an NC alarm, the num-
ber range can be seen in the following table:
Section 3 Find the description in the diagnostic guide
3.1 Find the description in the diagnostic guide
A description of the alarm can be found in the 802D sl Diagnostic Guide.

C41 Editing of NC Machine data
1 Brief description
Module objective:

Upon completion of this module you can locate the NC machine data, set the password and make
changes.
Module description:

During the life of a machine it may become necessary to change the values of certain NC machine
data. The necessity arises e.g. due to wear on mechanical components, the axis performance can
therefore deteriorate. In some case, further mechanical damage can be prevented with the help of
the NC machine data.
A change should only be carried out in conjunction with recommendations from the machine tool
builder.
Module content:
Location of NC machine data

Setting password
Changing machine data + data save

Location of NC ma-

chine data
Section 2
Setting password
Section 3
Changing machine
data + data save Section 4
Section 2 Location of NC machine data
2.1 Location of NC machine data Notes
The NC machine data is located in the System area. The system area can
EHHQWHUHGZLWKWKHNH\FRPELQDWLRQ³6+,)7$/$50´7KHIROORZLQJGH
scribes graphically how to enter the Machine data area:
Machine data
entry point
General MD
10000-19800
Channel MD
20050-29000
Note:
Axis MD Drive machine data should
30100-38000 only be changed under
supervision from experts
Section 3 Setting password
Notes
3.1 Setting password
In order to make changes to the NC machine data, the corresponding
password must be set. Certain machine data can only be changed with the
SERVICE or MANUFACTURER password, in this case, contact the builder
of the machine.
The following sequence shows graphically how to change/activate the
password.
Enter new
password
level
Change stan-
dard password
Password cancelled
Keyswitch active
Section 4 Changing machine data + data save
4.1 Changing machine data + data save
When the necessary password is activated the machine data can be
changed.
0DFKLQHGDWD¶VDUHHDFKKDYLQJDQDFWLYDWLRQFULWHULDWKLVFULWHULDGHWHU
mines when the new machine data value will become active. This criteria
is written in the machine data list next to the respective data.

Po = after powering on
Re = after pressing Reset key on machine control panel
Cf = after powering on
Im = immediately

After making changes to the machine data, it is important to make a
QHZEDFNXSVHHKDQGERRNPRGXOH¶V&DQG&


C53 Drive diagnostic parameters
1 Brief description
Module objective:

Upon completion of this module you can locate the Drive machine data, set the password and locate
the diagnostic parameters.
Module description:

In the case of a fault, it is useful to have an overview of the fault conditions which may be existing in
other areas of the control. It is often in the case of an axis alarm that a fault in the drive may be the
cause.
Module content:
Location of drive diagnostic parameters

Setting password
Location of drive diag-

nostic parameters
Section 2
Setting password
Section 3
Section 2 Location of drive diagnostic parameters
2.1 Location of drive diagnostic parameters Notes
The NC machine data is located in the System area. The system area can
EHHQWHUHGZLWKWKHNH\FRPELQDWLRQ³6+,)7$/$50´7KHIROORZLQJGH
scribes graphically how to enter the Machine data area and how to navi-
gate to the drive diagnostic area:
Status 0 =
ok
No drive error
existing
Section 2 Location of drive diagnostic parameters
Notes
6WDWXV
not ok
Operational
status
Further important diagnostic parameters can be found under the softkey
³3DUDPHWHUGLVSOD\V´7KHPRVWLPSRUWDQWSDUDPHWHUVFDQEHVHHQLQWKH
following table, and the values can be passed to the relevant service
personnel upon request:
Section 3 Setting password
Notes
3.1 Setting password
In order to see the data, the correct password should be set.
Enter new
password
level
Change stan-
dard password
Password cancelled
Keyswitch active

Complete Operating and Programming 802Dsl en A TM Sw1 4

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SINUMERIK 802D solution line

Machine Controller Handbook T/M

Training Manual Edition 2007.7

Training Material for none Metric Systems

Operating and Programming Service

Power On and Referencing C69 LED Diagnosis Drive C9

Control Structure / Navigation C70 LED Diagnosis HMI C10

Basic Program Structure C98 MCPA Board C11

Modality (preparatory functions) C89 Save Data Backup C17

Commonly used G functions -­ T C91 Restore Data Backup C18

Basic Miscellaneous Codes C97 Diagnose PLC program C28

Additional G functions -­ T C93 Diagnose PLC alarm C31

Additional G functions -­ M C94 Alarm structure C37

Cycles -­ M C99

Tools Turning²Milling functions C83

C101 CNC Basic Principles -­ Turning

Fundamentals of CNC Machines

Fundamentals of CNC

A referenced machine has a defined position.

When a work piece offset is activated.

When a tool offset is activated.

C102 CNC Basic Principles -­ Milling

Fundamentals of CNC Machines

Fundamentals of CNC

A referenced machine has a defined position.

When a work piece offset is activated.

When a tool offset is activated.

C69 Power on and referencing -­ Turning

Switch on the control

Switch on the control

Referencing the axis

Or by using the following sequence:

Care to be taken

C69 Power on and referencing -­ Milling

Switch on the control

Switch on the control

Referencing the axis

Or by using the following sequence:

Care to be taken

C70 Control structure and navigation -­ Turning

Overview of operating areas and modes

Overview of operating

Functionality of the

Screen layout Section 4

Standard softkeys and

Operating area Softkey Function

Operating area Machine Setting functions, Program control,

Program editing, Simulation, Cycle

Zero offsets, Tool parameters, R-­

Operating area Program-­ Managing the NC program

List of active alarms

Machine builder specific

Overview of the softkeys in MDA

Overview of the Softkeys in PROGRAM

3 Tip and softkey Area

1 Active operating area, active mode

2 Alarm and message line

4 Program control in Automatic mode

6 Selected part program (main program)

Tip and softkey area

3 MMC status information

4 Vertical and horizontal softkey bar

Commonly used G functions - T C91 Restore Data Backup C18

Additional G functions - T C93 Diagnose PLC alarm C31

Additional G functions - M C94 Alarm structure C37

Cycles - M C99

C101 CNC Basic Principles - Turning

C102 CNC Basic Principles - Milling

C69 Power on and referencing - Turning

C69 Power on and referencing - Milling

C70 Control structure and navigation - Turning

Zero offsets, Tool parameters, R-

Operating area Program- Managing the NC program

C70 Control structure and navigation - Milling

Zero offsets, Tool parameters, R-

Operating area Program- Managing the NC program

C98 Basic program structure - Turning

C98 Basic program structure - Milling

C89 Modality (Preparatory functions) - Turning

G function window dis-

Group 2: Non-modally valid motion, dwell

Group 10: Exact stop - continuous-path mode

Group 11: Exact stop, non-modal

Constant feed at internal radius, acceleration at exter-

C89 Modality (Preparatory functions) - Milling

G function window dis-

Group 2: Non-modally valid motion, dwell